2016 450xcf leak from case screw in plug?

[dirtydrew]

Picked up a 16 450xcf last weekend. Rode it a few hours today and noticed a leak from the countershaft seal as well as this small plug on the bottom front portion of the clutch side engine case. What is this plug for? Can I remove, re-seal and reinstall without disrupting anything on the inside of the motor? ( no spring or silly thing to shoot out if I remove the plug?)

Thanks guys

[TomTopDog12]

Picked up a 16 450sx-f myself this weekend and am just loving it so much. I haven't ran into that problem before but all i know is there is one screw that's a 13. It's one of the drain bolts with a screen, There is another bolt with a allen head. DONT REMOVE THAT. or at least that's what the KTM manual says. I'll keep an eye out for this on my bike.

 

 

Cheers and enjoy the new bike!

[dirtydrew]

Picked up a 16 450sx-f myself this weekend and am just loving it so much. I haven't ran into that problem before but all i know is there is one screw that's a 13. It's one of the drain bolts with a screen, There is another bolt with a allen head. DONT REMOVE THAT. or at least that's what the KTM manual says. I'll keep an eye out for this on my bike.

Cheers and enjoy the new bike!

Thanks for the reply. This is not a drain bolt, it's a tiny Allen headed plug, probably 4mm thread. The parts fiche shows three like plugs in the lower case halves. Not to be removed though?

[dirtydrew]

Upon further inspection, that plug does not have and Allen head and appears to be pressed in

[dirtydrew]

Is this a blow put passage for the connecting rod bearing?

[rcmxracing]

I can't recall where but there was mention of this in an article somewhere...MXA maybe. Don't take my word, but I think they said just remove and put some sealant and reinstall. Mine weeps a very small amount, needs dealt with.

[rcmxracing]

Here you go. Different location but I suspect same issue/fix. You mention no Allen head, but probably leak from nearby location that does have an Allen head.

https://www.google.com/amp/motocrossactionmag.com/news/ask-the-mxperts-my-ktm-leaks-oil-from-the-ignition-cover/amp

Edited November 15, 2016 by rcmxracing

[dirtydrew]

Thanks for that article. Seems to be a very similar issue, the plug on the 450 appears to be an oil passage plug as well. But it is definitely no threaded on the head. I'll probably just epoxy over it

[dirtydrew]

So I ordered the plug based on the parts fiche. It is a threaded plug with a torx head on it. It seems the screw in plug had some type of anti tamper plug pressed in over it. Should I drill it out and then unscrew the plug and re-seal? I already pushed some epoxy putty into the recess to try to seal it for the time being. But would like to fix it properly.

[mog]

I think it has a spring behind it ??

[dirtydrew]

I think it has a spring behind it ??

I think that is the larger Allen head plug with copper sealing washer on the bottom of the case for the oil pressure regulator

[rcmxracing]

So I ordered the plug based on the parts fiche. It is a threaded plug with a torx head on it. It seems the screw in plug had some type of anti tamper plug pressed in over it. Should I drill it out and then unscrew the plug and re-seal? I already pushed some epoxy putty into the recess to try to seal it for the time being. But would like to fix it properly.

I'm not sure I would drill into it. Unless that's the only option to get the plug out. Jack those torx up and you're not getting it out. Maybe wait until you get the bolt and take a look, meantime I would talk to a KTM mechanic. They have to know what's up with these. If you aren't near one take some really good pictures and email to MXA. I've gotten responses in the past. Other KTM forums out there also. I'll take a look at mine after I wash it and remove glide plate. Edited November 16, 2016 by rcmxracing

[FaintReality]

My dad has one ride (2.3 hrs) on his 16' Husqvarna FC 450 and it is spitting oil everywhere. Upon inspection, it looks to be the same as you mentioned. The bolt under the engine with the crush washer/torx head as well as behind the counter shaft sprocket.

I dropped it off at dealer yesterday and requested it be fixed under warranty as the bike is brand new.

[dirtydrew]

I'm not sure I would drill into it. Unless that's the only option to get the plug out. Jack those torx up and you're not getting it out. Maybe wait until you get the bolt and take a look, meantime I would talk to a KTM mechanic. They have to know what's up with these. If you aren't near one take some really good pictures and email to MXA. I've gotten responses in the past. Other KTM forums out there also. I'll take a look at mine after I wash it and remove glide plate.

I've got the bolt and it's definitely a little torx head plug, but it did not include the anti tamper cap/ plug. I put some epoxy putty over it for now. Haven't ridden it yet, but if that stops the leak I'll probably just call it done. Sucks to have that epoxy crap on a newish bike though, kinda hokey

[mog]

Why does it need the anti tamper head on the new one ?

[dirtydrew]

Why does it need the anti tamper head on the new one ?

It doesn't, I'm just worried about messing the screw in plug up while trying to take the pressed in cap off the top of it

[rcmxracing]

This thread has run its course but putting some pics up for info. This is from a 16 450 SX-F. There are no Torx just Allen head plugs. Didn't see any anti-tamper either. The "leak" is minor after 25 hrs.

[dirtydrew]

This thread has run its course but putting some pics up for info. This is from a 16 450 SX-F. There are no Torx just Allen head plugs. Didn't see any anti-tamper either. The "leak" is minor after 25 hrs.

📎IMG_1480010344.826275.jpg📎IMG_1480010362.093542.jpg

Look at the front of the case behind the skid plate. Not the bottom of the case. There are three tiny plugs that cap oil passages. These are not the oil drains or oil pressure cap/ spring assembly. I placed a little epoxy over one last week and it has not leaked again.

[rcmxracing]

Smaller plugs, plugs everywhere. No leaks on mine. Glad to hear the leak is fixed.