KTM 450 - 530 Oil Pump Upgrade! How To Article with Pics

Discussion in 'Thumpers' started by Hodakaguy, Jun 14, 2011.

  1. uncktruck

    uncktruck Adventurer

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    Jan 28, 2015
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    60
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    Valley Center, California
    Once again, you're the voice of reason. Thanks for all your help, I have to run to town for oil, I'll let you know how things work out.
    #81
  2. alongat

    alongat Fesh Fesh

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    Let me know - good luck. I'm currently in the UK but if you get stuck somehow, text me at 14169307405
    #82
  3. akarob

    akarob Rob

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    Skuncasville, CT
    Does anyone have a picture of the Kickstart idler gear to share? Sounds like a good thing to check. Thanks.
    #83
  4. alongat

    alongat Fesh Fesh

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    image.jpeg
    #84
    akarob likes this.
  5. uncktruck

    uncktruck Adventurer

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    Jan 28, 2015
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    60
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    Valley Center, California
    Thanks for all the advice and illustrations, bike fixed and time will tell if it holds.
    #85
    JoshMurray likes this.
  6. uncktruck

    uncktruck Adventurer

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    Jan 28, 2015
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    60
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    Valley Center, California
    alongat, thanks for your help! Your advise had a calming effect on this old guy which helped get the bike fixed and back on the road. I only have a few miles on it so far, I'll let you know how things go after a 100 or so miles. Thanks again!
    #86
  7. alongat

    alongat Fesh Fesh

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    Excellent, it's my pleasure - I'm sure it will be fantastic.
    #87
  8. Yedmod

    Yedmod Adventurer

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    MadJackistanni Ambassador to Iowa

    Don't try to put it together with the roller bearing and the steel bushing in the clutch basket. The easy way is to first slide the steel bushing (#3 in the link below) on the shaft (leave the roller bearing off). Next put the clutch basket on. Without the roller bearing on the bushing the basket can move around a little and it will go right on. After it is on the roller bearing (#2) can be slid into the space between the clutch basket and bushing from the front. Everything falls right together that way.

    http://www.partspitstop.com/oemparts/a/ktm/524b8dc0f8700231ac498c70/clutch
    #88
  9. uncktruck

    uncktruck Adventurer

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    Jan 28, 2015
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    Valley Center, California
    Hodakaguy and alongat, thanks for the help. The bike is fixed and I think it'll do the 2,000+ mile dirt ride I'm about to undertake. Thanks!
    #89
  10. alongat

    alongat Fesh Fesh

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    Nice - enjoy and be safe.
    #90
  11. uncktruck

    uncktruck Adventurer

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    Jan 28, 2015
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    60
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    Valley Center, California
    Alongat, the bike ran flawlessly during the entire 1907 mile trip. The only hiccup was when I laid it down in a river crossing, had to clean every electrical connector on the bike before it would fire. I've really grown to love this bike.
    #91
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  12. mbillens1

    mbillens1 Been here awhile

    Joined:
    Aug 29, 2009
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    115
    Thanks for the detailed thread -- I bought a used 530 exc that had most of the upgrades done already, but it was good to open the bike up to check. Also had the kick idler spun bushing problem I needed to fix.
    #92
  13. AusMuppet

    AusMuppet Adventurer

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    Feb 5, 2018
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    Canberra, Australia
    Thanks for the great write up!
    I've got some Blais racing gears and all the other gear needed on the way for install. After spending the time and money on the SXS big bore kit I decided that spending the extra money on this would be worthwhile protection.
    #93
  14. Ronic

    Ronic n00b

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    Dec 15, 2018
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    Israel
    Hi Tom , i need to replace also My clutch im using not OEM plates should i remove the 2 x spacers disks ? the one that first installed in the clutch basket. i attached your picture , i also noticed different metal plate that has deep engraving someone know if it should be like that ? ill mention that i have a problem in cold start placing 1st gear and bike turn off . only when it warm up im able to enter 1st gear

    Attached Files:

    #94
  15. akarob

    akarob Rob

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    No, that plate should not be like that. That wear is from the large spring washer that mates up against it. Just swap that plate out with one of the other ones.

    The OEM assembly has two large washers - one is flat and the other is a spring washer.
    #95
  16. Finnyfire

    Finnyfire Jedi Master

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    I have a question. I am replacing the oil jet on my 08 to the 125. The fiche shows 2 of the same jets. Where does the other one go? Do I need to worry about upgrading the other one? Thanks.
    #96