Ktm 150 rings replacement

Thanks a lot guys for all the help.

Hello, i am stuck again, near the end....

I am having a big problem with the kick start spring when bolting the whole clutch cover to the case. When i bolt the cover to the case, the kick start wont go back to up - to the original position. When i loosen the bolts on the cover, the kick start goes back up. It seems I am 'pinching-hopefully that's the word' the spring on the area, where the end of the spring goes in to the hole....there is too little space on the clutch cover for the spring....I could grind out the cover so the cover would not be pinching the spring...but originaly the kick starter worked fine so maybe i am doing something wrong...

I would appriciate any help...




its marked with red where i think the problem is

Thanks again....

the plastic/rubber bushing underneath the spring wasnt oriented correctly, it has a little notch for the spring to sit in....i positioned it correctly and sure enough the cover bolted effortlessly.

Man oh man....

The engine is now assembled and runs ok, but i just noticed a nice little tranny oil leak from the clutch cover case, underneath the bolts...i've put the gasket on and off quite a few times when i was having trouble with the kick start spring....it wasnt damaged for sure, but i bolted and unbolted it probably 10 times...is that bad for a gasket? Should I buy a new one?

I just ordered it...will report back when i put the new one on. I am guessing if I put a little sealant on, could I still reuse a the old gasket?

Put brand new gasket on, tightened it to 15 Nm...and still a leak. I checked both sides if the case, both seem fine...i even have a very fine polishing stone, went over the contact surface area of the cases.....

The only thing that I possibly could have done wrong, is maybe slightly bend the cluth side of the case when i was tightened it before, when the kickstart assembly wasnt oriented correctly...althou not very likely...

Now im gonna put it back apart and use some silicone with the gasket, hopefully that will stop the leak.

So i have a little update...I am at a point where i'll either learn or pour gasoline over the bike and burn it....

Anyway, once i put a thin layer of silicone under the gasket i was able to stop the leak....and another thing i learned the hardway...dont ever tighten the case screws over 10Nm...you'll have a ruined day. Aluminium strips really fast.


The thing was thou, everytime I started the engine, there was a lot of smoke coming out of the exhaust. At first, it seemed fine once the engine has warmed up, the smoke cleared. But after a while, it was just spewing oil out of the exhaust. From the silencer and even from the front - from the cylinder. When I took the exhaust off the bike, i could pour like 0.5 dcl of oil out of the exhaust.

So it turns out, that either the crank seal is leaking or the main gasket of the case is leaking and the oil is coming to the cylinder. So i took the right side-the cluth side- of the case off to inspect the sealing (btw of course i installed new seal when I replaced the crank and bearings + i thought i was very careful when installing it), and the sealing seemed fine.

So no other choice than to disassemble the whole engine again to inspect the main gasket.




The stator side of the case was completely dry. But there is definately oil on the clutch side of the crank space. It is 'watery', probably mixed with gas from the carb. So this leads me to belive there actually is a crank seal leak.



The is also a tiny groove on the crank ring that goes into the seal...is that worn and should be replaced?

Well, it aint easy being a mechanic, thats for sure!

Hello,

yeah, the o-ring was definately under the sleeve. I also took extra care how i put the whole seal into the case...I genlty pushed it into hole with my hand, than put wood over it and slowly hammered it the whole way in. It was 100% sure oriented correctly. Did I oil the sleeve before i pushed it into the seal?Probably, but I'm not 100% sure.

I'll change the main case gasket and the seal on the clutch side and report back.

A little report:

The groove on the crank ring was definately a no-go, as the new one i bought does not have any....but it still did not solve my problem....

for a while I thought it was a little better, but after 0.5 hours of the bike running, i am still having the same issues:
- bike is spewing oil out of exhuast;
-white (burned oil) smoke coming out of exhaust- a lot of it,
-it stops idling after a minute or so, totaly bogs down;
-doesnt want to start, unless i take the spark plug out and clean it, then is starts in second kick, but the bogs down after a minute....
-when i take the exhaust from the bike, the oil pours out of it (the cylinder side)

The list of the things i've done:
- new middle case gasket
-new crank seal (cluth side)
- new crank ring (comes in the seal)
-new clutch gasket with sealant underneath;
-the premix is as per manual and the bike ran fine in the past, so i know the carb is not the issue;
- the coolant is the same level, it doesnt leak;

My next thing to do, is to disassemble and clean the power valve area in the cylinder.

After that i have no other idea, why or how would the transmission oil come into the cylinder???