Leaking camshaft/water pump seals.

djebel250 · Dec 25, 2001

Few days ago. I noticed that there are oil stains leaking from my 01 ktm400exc's water pump whee hole. so I took it apart and changed the seals, "o" rings and camshaft bearings as-well. Jus after riding it for half and hour. it leaked again!!:ugg: So I took it apart again!!! changed the whole seal housing" the aluminium peice that holds the seals and "o" ring" But to my disappointment. it leaked again this morning. :mad: i really don't know what to do next. some people suggested to me by putting another "o" ring on the middle grove of the aluminium housing. but i m woried that if the whee hole is sealed, the coolant and oil will mix if the seals were to leak. without me knowing!!! any suggestions?

colorado-high · Dec 25, 2001

You need to press the seals into the carrier as straight as possible. Do not use a socket and hammer or a vice.I went to the local auto machine shop and used their hydraulic press to press them in.They went in very straight.If the seals dont go in straight it will distort the lip. You need to use the thinnest gasket material you can find, such as Loctite 515 is the prefered sealant the next would be Yamabond4.Use as a small amount as possible and only on the rocker cover do not put any around the seal carrier.Make sure to use the special tool when you install the carrier on the cam(very important).Also apply a little seal grease(Bel-Ray or White Bros.) to the seals.Your coolant level should be to just over the fins in the radiator do not fill to the top of the neck.If you need more info go to holeshot.com and do a search under the forstroke forum.

OLD STROKER · Dec 25, 2001

I've fixed a number of KTM's with water pump leak problems. Check out my post on Holeshot's 4 stroke forum, entitled...Waterpump seal NO FIX on 2002, dated 11/19/2001

Good Luck
Old Stroker

djebel250 · Dec 26, 2001

Colorado-high. thanks for the advice. the seals were pressed in straight. as for the gasket. i used a gasket maker normally used for sealing gearboxes and rocker covers. I m still monitoring the leakage. but it seems to be getting lesser leakage as the days goes by. will check it out tomorow.
Thanks OLD-STROKER. btw, whats the web page address? can't seem to find it.

OLD STROKER · Dec 26, 2001

Sometimes when you think you've got the seal pressed in straight, you really don't.I went thru this a number of times before I made a tool to press them in.Since then I've had a 100% sucess rate.In addition the sealant should be Loctite 515 gasket eliminator. It provides a very thin coating, allowing the valve cover to compress completely and provide a good seal on the o-rings.
The tool is to costly to produce for sale, but what i've been doing,is to have people send me the seals and carriier and I'll press them in for them. You can e-mail me at thumpall@aol.com if you're interested.
Here's the web site where you can find my post... http://www.holeshotforum.com/cgi-bi...um=4-Stroke+Forum&DaysPrune=100&startpoint=75

djebel250 · Dec 31, 2001

wa went wrong?

Jus took out my rocker cover and seal it up with loctite 515. At first, I applied a thin layer. Covered it up and begin fixing all the part back. upon filling in the coolant. i noticed coolant leaking out from the whee hole. Wat to do? I opemed it up again.... apply a thicker coat of loctite 515 and wait for it to cure. waited at least an hour and half. covered it up again and...etc.etc. took it for a ride till it's real hot. Then to my disappointment. it's still leaking.:(
can somebody advice wat is the curing time of the loctite 515 gasket eliminator? can't seem to fix this problem.itz really killing me.:uh: thanks alot guys.

colorado-high · Dec 31, 2001

Are you putting Loctite on the seal carrier??There should be NO sealant that touches the carrier it is just to seal the mating surface of the rocker cover.If you get sealant on the carrier the o-rings will not seal correct.You must be perfect when you put it back together.Did you use the 'bullet" tool to install the carrier on the camshaft???If not you damaged the seal and need to start over.Go to the holeshot board and follow Old Strokers directions to the letter.

Leaking camshaft/water pump seals.

djebel250

colorado-high

OLD STROKER

djebel250

OLD STROKER

djebel250

colorado-high

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