Oil Leak KTM 525 EXC

[56BelAir]

I have an oil leak on my bike where the countershaft sproket goes. I replaced the seal and it still leaks the same amount if not more. It is a bad leak, not just a few drops. Any ideas on exactly what parts need replaced besides the seal itself?

Paul
Parker, CO

[56BelAir]

I replaced my counter sprocket seal for the second time. Originally the leak was really bad. After I replaced the seal the first time the leak was really, really bad.

This is the second time I replaced it. I cleaned the seal, the shaft, and the casing where the seal seats. This time I put a little light coating of RTV black around the seal in an attempt to help.

I am trying to find out if an oil leak from this area is a known problem. If it doesn't get fixed this time I will go ape sh!t. I also replaced the o-ring, and lubed the seal with a light coat of oil.

Thoughts?

Paul
Parker, CO

[exc92]

I have a 250 exc., IM so glad im not the only one that the countershaft sporocket seal leaks.It started out ,a slow leak.the seal look good.I carefully removed everything, Cleaned the shaft with wd40,Lightly greased shaft and seal,It still leaked.Now I've put a new seal on,and now,it leaks worse.It SUCKS! I have no idea what to do now.And its all over a simple countersprocket seal getting replaced.Ive done topends,a little in total engine teardowns,and I know my way around a motorcycle.But this leak is about to drive me crazy.Would having too much oil in crankcase cause this?

[56BelAir]

I put RTV black around the perimiter of the seal. That seemed to do the trick. That was the second time I replaced my seal. When I replaced it the first time I made it worse somehow.

[WHITECA]

Originally Posted by 56BelAir

I have an oil leak on my bike where the countershaft sproket goes. I replaced the seal and it still leaks the same amount if not more. It is a bad leak, not just a few drops. Any ideas on exactly what parts need replaced besides the seal itself?

Paul
Parker, CO

I am having the same problem with my 2007 525exc. I have replaced the shaft seal and the leak has slowed, but has not stopped.

Like paul, I would like to know if there is another solution for this leak.

Thanks,

WhiteCa

[flyer15015]

Originally Posted by 56BelAir

I have an oil leak on my bike where the countershaft sproket goes. I replaced the seal and it still leaks the same amount if not more. It is a bad leak, not just a few drops. Any ideas on exactly what parts need replaced besides the seal itself?

Paul
Parker, CO

Paul,
The only ways oil can get out, is too small a shaft, or too big a seal.
Check the shaft for a groove. if found replace.
Check local parts houses or industrial suppliers for a smaller seal.
Sometimes an american (sae) seal is just enough smaller than it's metric counterpart that it will work.
mike
buena vista, colo

[exc92]

Having just alittle too much oil in crankcase would cause it to leak.Also,a aftermarket front sprocket is thinner than factory,which would not make a good seal against the oil ring.I had renthal front sprocket ,I could move in and out ,oil would look like it was coming out of the c-clip.I put a KTM sprocket, no oil leak,and Icould not move it left or right anymore.

[56BelAir]

Got it fixed. I took it into a shop, not sure what trick they did to get it to stop.

Paul
Parker, CO

[peterbuilt]

just went through this ..KTM says to reseal ignition case with jb weld ..apply on engine side only ..for future removel.i went through 3 seals before i found out where the leak was coming from.the ignition side has oil in to ..just a new gasket wont help..if you can find one anyway.i did what they said and now ive got a nice clean engine again.

[richardscott]

Clean the area with degreaser. Check your oil levels, and take it for a ride. When you get home play detective. Let it run out and get down there with a flashlight and find out exactly where it’s coming from. Hope you didn’t crack the case when the chain broke. Might just be the seal for the clutch slave. Could be be the seal behind the front sprocket. If it’s really had to figure where it’s coming from, you can clean, dry, and then spray with some of that foot powder you have lying around in the medicine chest. It comes out white, and the oil will leave a trail through it.