Replacing base gaskets (fixing oil leak)

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limeyduffa
900cc
900cc
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Country: Australia
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Year: 2012
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Replacing base gaskets (fixing oil leak)

Post by limeyduffa » Sat Apr 07, 2018 3:06 pm

All

The base gasket on my front cylinder is leaking. I am investigating repairing the fault myself. I have done some googling tonight. There's a thread on the 990 Superduke forum that mentions under-engineered head studs that stretch and cause this leaking. What are people's opinions on this ?. Is it something that still effects later year 990 builds like the SMT ?

http://www.superduke.net/forum/viewtopi ... e&start=25

I am going to remove the front retaining engine bolts, drop the engine out of the frame, while leaving the swing arm bolt in place. This will allow access to the front cyl. Looking at the service manual and reading google search recommendations, I'll need to order the following parts:

1 x 600 30 035 000 CYLINDER-BASE GASKET FR 0,35MM
1 x 584 30 074 000 CIRCLIP 22 X 1,6
4 x 600 30 043 100 STUD M10X161 06
4 x 600 36 078 050 SHIM 10,2X19X1,5MM 05
4 x 600 36 078 200 COLLAR NUT M 10 WS=13 05
1 x Rocker cover gasket ??? (Can't buy individually - comes in a $379AUD gasket kit !)
1 x Special tool - Box wrench attachment 13 mm 60029081000

The recommendation is to replace the circlip (I remove), as well as all studs, stud washers and bolts (they are "one time only" apparently).

Has anyone got any comments, experiences on this job ?. I noticed that I'm only 1 of 2 users on this forum that have this problem. My bike is 6 years old (2012 SMT), with 37800km on the clock.

Are there any Australian users who have the box wretch tool I could borrow ?. It's $165AUD. Not to be sarcastic, but I'm guessing it's an endless back order wait from KTM Australia.

Cheers

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limeyduffa
900cc
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Joined: Tue Mar 15, 2011 9:22 am
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Re: Replacing base gaskets (fixing oil leak)

Post by limeyduffa » Tue Apr 17, 2018 12:54 pm

...

JET KTM
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Re: Replacing base gaskets (fixing oil leak)

Post by JET KTM » Mon Aug 27, 2018 8:01 am

Hi mate. How did you go with your issue. I have a leak from my rear cylinder base gasket. 2009 model. Keeping a close eye on it. Seems to be a common issue after google searching, more so with the earlier 950 and 990 engines. Let me know how your one ended up. I'm planning to replace mine at 50,000km when I do a valve adjustment. Exhaust valves currently at the tighter end of spec at (40,000kms currently) When you stripped it down, did you notice any corrosion on the engine case gasket mounting surface?

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limeyduffa
900cc
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Posts: 324
Joined: Tue Mar 15, 2011 9:22 am
Country: Australia
City: Adelaide
Year: 2012
Colour: Black
Model: SMT

Re: Replacing base gaskets (fixing oil leak)

Post by limeyduffa » Thu Aug 30, 2018 6:53 am

Yeah, success. Documented here:

viewtopic.php?f=13&t=11853

No, I didn't notice any pitting the ADV and SD sites mentioned. Surfaces where in excellent condition. The oil leak was leaking pas the gasket. I had a chat to my KTM dealer mechanic 2 months ago. In his opinion, the theory that the studs are stretching is false, as the head gasket would be the first thing to go if that happened.

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