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Discussion Starter #1
Had a run out on the bike yesterday & all was well.

I just went to go for a quick blast then & when I started it up I thought this lights taking a while to go out & it's getting noisy, probably ran for 10 seconds. So I crapped my pants & turned it off.

I thought let's give it another chance & tried again but the light kept flickering so I shut it down.

I quickly checked the oil level & it seemed a bit high.
Bikes done 30,000 & I've had it for 13,000.
didn't have time to check much more after that as tea was getting cold round the parents house!
Where should I start looking? Oil filter?

Mrmorg
 

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Water pump seal?

Take the outer clutch cover off and look for white goo inside it.

Take the oil filter out and see if it's wavy.
 

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With Kev, coz he's knows everything!!! Clutch cover off, only takes 10 mins and gives you peace of mind. Lost any coolant?
 

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Discussion Starter #4
Cheers kev, I will drop the oil tonight and start looking. Is there a guide anywhere for doing the waterpump job?
 

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Discussion Starter #5
Yeah I have lost a bit of coolant but I was thinking that might have been down to boiling my bike stuck in the bogs two weeks back
 

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If you fancy a quick fix, drill 2 holes in the old seal, screw in a pair of sel tappers and pull it out



Cheaper and quicker.... so long as your bearings are OK
 
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Discussion Starter #10
clutch cover looks like this. not much sludge building up but a little, is this enough to cause low pressure?

 

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Discussion Starter #12
:(


any idea of the best way to buy the kit? that cj designs kit is £140 on zenoverland!

maybe get away with just buying the shaft & seal from local shop?

im guessing the shaft might be worn as I'm guessing its 30,000 old
 

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Tis fooked, shaft, seals and bearings from Ktm for me.

Shaft will be worn, do it right, do it once.

Good for at least another 30,000 then.
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60030025000 CLUT.COV. GASK. INSIDE KLI.SIL 1
0770250030 O-RING 25,00X3,00 NBR 70 2
61135054044 WATER PUMP SHAFT W. SEAL RING 1
0625069010 GROOVED BALL BEARING 6901V C3 2
0471120010 CIRCLIP DIN0471-12X1 2
0472240120 CIRCLIP DIN472 D=24X1,2 1
61338015000 OILFILTER 2014 1
60035053000 WATER-PUMP GASKET 03 1


about £70 for the lot
 

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60030025000CLUT.COV. GASK. INSIDE KLI.SIL1
0770250030O-RING 25,00X3,00 NBR 702
61135054044WATER PUMP SHAFT W. SEAL RING1
0625069010GROOVED BALL BEARING 6901V C32
0471120010CIRCLIP DIN0471-12X12
0472240120CIRCLIP DIN472 D=24X1,21
61338015000OILFILTER 20141
60035053000WATER-PUMP GASKET 031


about £70 for the lot
That's the fecker.

Cj kit? Don't see the point.

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Discussion Starter #19
ok cheers for the info kev, i will get on it. can anyone recommend cheap place to get ktm parts online? i normally go to triple d but I'm sure they charge a lot.

i will probably have a go myself Charlie, keep me off the streets!

if its lasted 30,000 on the original kit I'm sure it will do 30,000 again so i dont see the point in the cj kit either
 

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ok cheers for the info kev, i will get on it. can anyone recommend cheap place to get ktm parts online? i normally go to triple d but I'm sure they charge a lot.

i will probably have a go myself Charlie, keep me off the streets!

if its lasted 30,000 on the original kit I'm sure it will do 30,000 again so i dont see the point in the cj kit either
Treat the case carefully when putting the new bearings in, seen some butchered. Support the bearing housing, think I used three bits of wood. You don't need any fancy stuff to remove the impeller, remove the whole case, support the case around the impeller..couple of bit of wood. Remove the rear cir-clip on the shaft and using a punch or fat screw driver knock the shaft out...this will remove the seal aswell cos of another cir-clip.....put the shaft in a vice and easily undo the bolt, loosen the vice and knock the shaft out out.......No idea why the manual shows all these special techniques....if you're replacing the shaft.
 
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