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Discussion Starter #1
On the bottom of the sump are 2 bolts one for gearbox oil an one for engine oil screens, When trying to remove one I managed to round it off, I had to use all my force to try an get it free but it would not shift.
Then the inevitable happened, rounded...

Now I know KTM are renound for the butter bolts but is there anyway I can avoid this in future?
Any tips on removing the little round beggar?

Thank in advance...:)
 

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Discussion Starter #4
Get new set and be careful not to over tighten them next time.

Gear oil screen and engine oil screen are 20 Nm but I set less on my torque wrench and they newer leak.
Be careful with smaller bolts too; oil filter cover screws are only 10 Nm, gear oil level check one is only 8 Nm!
Yeah I use a torque wrench and the workshop manual. But it was the previous owner who did em last.
I did hear from a bike mechanic that due to the bolt being ally and the sump steel the two expand and contract at diffrent temp thus dragging the sump bolts in.
 

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Undo them when the engine is proper hot, lay the bike on its side if you have to so you can see what you are doing.

Put a socket on and give it a couple of solid hard bangs with a hammer before undoing.

Use a good quality 6 sided socket or torx

Smear the threads with copper grease.... the correct torque reading is just enough to nip the O ring.
 

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Did you get it out I have same problem, local KTM dealer are asking about £400 to get it out with the possibility of it costing £800 if case is damaged.
 

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Did you get it out I have same problem, local KTM dealer are asking about £400 to get it out with the possibility of it costing £800 if case is damaged.
Wow :eek: I'd drill it out before paying that. Then re tap it or pay someone to re tap it.

The guy who works on my bike said it'd take him 5 - 10 mins and shouldn't be a problem. He said he'd done a few.
 

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I have got plenty out, never had to resort to drilling.

Normally a few good bashes, then tap it round with a dot punch. I had one that was really bad, but TIG welding a bolt onto it got it straight out :)
 

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Discussion Starter #9
I have got plenty out, never had to resort to drilling.

Normally a few good bashes, then tap it round with a dot punch. I had one that was really bad, but TIG welding a bolt onto it got it straight out :)
Yeah as I thought, it's not the end of the world, gonna have a go at it my self today if it doesn't come out I will have it removed Monday by a profeshanimal...

Either way I don't expect to pay over £30/40 squids to see it out.
 
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