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06 525 exc leaking oil front sprocket

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i had replaced my front and rear sprockets

i cleaned all the crap from the front sprocket installed the new sproket

but now noticed it leaks oil ( behind the front sprocket ) is this a big job

cheers Phil

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I'm having the same problem. There are a lot threads on here about it though. Depending on your mechanical skill level, it shouldn't be too bad of a job. I just picked up my 450. The previous owner swapped the sprockets and now it leaks. I'll be doing the repair myself. I'll try to make a DIY article when I'm doing the job, so others can have some instruction. If you figure it out first, let us know.

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One thing to watch is some aftermarket front sprockets are too thin and that can cause a leak, the cupped washer needs to preload the sprocket. Also make sure you are not running the chain too tight.

Ed

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remove the sprocket, pull out the bushing and clean the inner lip of the seal with a q-tip, buff the bushing with emery cloth, replace the o-ring. The other parts to this are pressure pushing inward to create the seal. So the sprocket has to be the right thickness and the washer has to have its spring tension too. The washer can be "re-cupped" by using a large socket or something with a hole in it to put the washer on. Then hit the washer with a ball peen hammers round end to give it its cup back. May have to hit it a couple of times to get it cupped. Has worked every time for me. No new parts except o-rings and a washer now n then.

Edited by Mike in Fresno

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Just an idea, Im assuming your sprockets are worn out, if so you may want to consider changing the counter shaft seal, bushing and bushing o-ring seal, while your at it get a new spring washer (re-cup the old washer and keep as spare), I dont know how many hours you have on your bike, or how and where you ride it, it might be a good idea changing out these parts as preventive maintenance, its not expensive, the job is not hard, but if you have never done it before, you may be a little apprehensive in doing the job, pick up a $10 seal puller to make things easier, if you choose to go this route and get confused, just post it and many will jump in to help.

P.S: I highly recommend using KTM made front sprockets only as suggested by others.

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those seals are really hard to pull out...

I bought an o-ring and another piece, i assume its the washer you're all talking about. its a gold ring. I can see the old "washer" but I can't get it to come loose. I pulled out the silver ring that was around the spindle. My oil is draining, but I cannot seem to get that washer loose to replace it. any ideas? (im too cheap to get a seal puller.)

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I got it done, it was a pain in the but prying it out, probably better to get the right tool for the job. It wasnt bad after that. Just be careful not to break your chain's master link clip like i did...

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too bad you went thru all the trouble cuz it probly didnt need to be replaced, its your money n time tho

it cost me a total of $6 for the seals.

$12 total if you include the price of breaking my master link.

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The good thing is, your now familiar with the job, its one of these piss off damned if you do or damned if you dont jobs, but for sanity sakes get a seal puller, the seals out in seconds, some people drill holes and put screws in, but you have to be real carefull, is what I use and it costs $10, it makes the job alot easier, faster and less prone to mistakes.

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well I had no idea the seal was so cheap, seems it was 12 or so when I did it once on my 200. Any way, next time remember to just use a qtip and clean it, it will fix it 99% of the time

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If you are too cheap to buy a seal puller, you can drill 3 small holes around the seal. Then drive in 3 drywall screws and use them to pull the seal out with the claw end of a hammer.

Make sure you don't drill in too deep or drive the screws in too deep!

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does it have a stock KTM part sprocket and did you get a new washer?

I assume its an aftermarket sprocket (it came on the bike), and no, I did not get a new washer. If its the washer's fault, I can do that. I dont want to replace the sprocket though, just to fix a minimal leak.

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With one hour on my new bike I changed the front sprocket to a KTM hard parts sprocket with less teeth. It started spraying oil from the shaft behind the front sprocket. Turns out I just need to bend washer to have more pressure on the sprocket and has not leaked since.

Like most that have posted I believe the majority of the time you do not need to replace all of the seals.

It is an odd set up that it needs pressure on the seals so they do not leak oil.

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you have the info on what to do, dont be afraid to spend a few dollars to fix what was probly the original problem instead of the seal

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