Man, I keep coming back to watch your videos, because you give the best advice. "Sit by the campfire, and drink a beer" - Seriously great advice about a problem that is minor in the grand scheme of things.
Great video Jeff. I have a 2020 and I have tried to fix this 4 times. This is my observation. Take it for what it is worth. You have WAY more experience than I do with this kind of stuff. I did the same thing that you did and still leaked. I finally took off the inner clutch cover and removed everything including the rubber piece that you siliconed. I notice right away that the cylinder head actually sticks out slightly from the case. Just a hair. It always seemed that oil was coming from this spot. I applied a very, very thin layer of silicone to even out this area and it worked and has not leaked since. Next time you have this are broken down please look at it and see if yours is the same. To me, there should be no tolerance between the head and case, but there is. At least on mine. Hard to explain and I hope that I am clear on explaining this.
@@Michael_Douglas007 I do not have pics. It is hard to explain but take the whole inner clutch plate off and you will see the area that surrounds what he is working on in the video. On mine, there was a very small gap. I applied silicone to this area. You will see what I am talking about if you take the inner clutch cover off. I think this gap was created by warping some from excessive overheating. This is just my thought.
@@davidreed6145Maybe engines differ in this area slightly. I'm assuming mine is quite a large gap because i have this exact leak and i haven't finished my run in 3 hour period yet. I'm in two minds about either tearing it down, or getting the shop to tear it down and fix it for me. I can see the issue is not too difficult to fix, but it shouldn't really be happening on a 2 hour old bike that has been ridden gently
You are awesome for showing this video, My 2023 gas gas EC250 was doing exactly that, I don't have to drive fir 3 hours to have somebody else fix it and worry about voiding my warrenty, I'll do it myself. Have a great day
Jeff, I assume you are working on a 2020 bike in this video. I believe this is a temporary fix, the problem is the sealing element (grommet) on the 2020's is smaller and is causing this leak. The permanent solution is replacing the grommet with a 2019 one that is larger. I sealed my PV cover the same way you showed here and it lasted about 40 engine hours before it started leaking again.
Jeff Slavens ktm changed the part number when they found out about the issue. New part was a one piece design while the older is three pieces. Look on my Instagram you can clearly see the difference in size between the two. Since I changed the parts I have no leaks and have not used any silicone.
It seems like people think that this is an issue unique to the 2020 and newer KTM 2 strokes, I'm not sure why everyone is so worried. I had this same problem on my 2009 300 XCW when I got it 4 years ago, and used silicone to fix it like you. It didn't leak at all between the 150-200 hour top end rebuilds. Cheers.
I was irritated to find that on my 2021 TX300 I also had an oil leak around the power valve cover. It wasn’t low on the cover around the D seal, it was higher up and around power valve bolt stop on the front of the engine next to the exhaust spring tab. Long story short, I found that the root cause of my leak was that the vent hose that runs from the top of the power valve cover into the air box was kinked at a sharp 90 degree angle where it went into the air box. It was kinked tight enough that there was a crease in the hose after I straightened it out, so there was little if any venting taking place. If you having oil leak problems,check your vent hose.
Hi, just saw on PNW Enduro channel that the 2020 grommet is smaller and shall be replaced by the 2019 grommet which is bigger. The 2020 part is now replaced by 2019 part.
I did the same thing for my daughter's 85. They are very similar, except the 85 has a gap between the bottom of the cover and the cylinder which is impossible to clean, so I filled that gap in with silicone as well. I also replaced the bolts that hold the cover on with hex head titanium bolts because the stock ones are very soft and nearly stripped out on me the first time I took them out. Titanium ones of this size are inexpensive.
You Tube is really amazing, it seems like they got every problem known to man on it. I have the exact thing happening on my bike. And man it is hard to see where the oil was coming from with the pipe & skid plate in place, just as Mr. Slavens mentioned. Of course my eyes aint what they used to be , but after disassembly last weekend I did confirm it was the same spot. I was considering the silicone repair but ordered the cover gasket & rubber piece they call the "sealing element" in the KTM parts list. Does anyone think they should also be replaced. ??
i got a 2023 te 300 bought it when i was 18 btw, 22hrs later had this leak. took it in under warrenty took them 4 weeks to get it fixed. they replaced the power valve gasket. ive had it back for a few days. rode two days leaking again. im trying to decide if its the power valve like u showed or if its my main seal at the bottom of the jug. im supposed too leave monday for 14 days before i start college again. so now i have too try and decide if its major being the jug too bottom end seal or minor being the power valve seal. either way the dealers geting a ear full for damn sure.
@@slaverace1 far from the same. Rocky mt atv part# 55537091000 sealing element. 2019 rocky mt atv part#54837091100 sealing carrier 07, 2@ part#54637107000 sealing element bottom. 2020 is one piece and IMO very week and shitty. 19 is 3 piece and the carrier is bulky and strong.
@@marlinbeach6982 Marlin, no idea what we have going here because I looked at the KTM factory dealer website (only accessible by dealers) again today to verify. The 546 and 548 numbers you list above are listed on every 250/300 microfiche from 2007 (250SX) to 2021 250/300 (all models). I own 2 2020 models, 1 2019 and my buddy has a 2021 and they all have the 3 piece (2 sealing rings and 1 carrier) units that KTM has used for years. I have yet to see the one piece 555 style but don't doubt it is out there. Also, 2020 and 2021 are not the only years that have had leaking issues. I've seen this issue since 2008. I just cleaned mine with contact cleaner, applied silicone seal and problem solved. Not trying to beat this horse to death or start a feud, just stating what I have seen and researched on the KTM dealer site.
I have a 2020 TE300 and fixing the leak from the power valve cover is only half the issue. The second place these leak is from the PV stop screw on the front of the motor. Jeff, can you please do a video on that. My guess is the head needs to come off for that.
Dirtrider Xc300 not an issue at all. That silicon will separate so easily when you take off the cover. And what's nice about silicone, in 5 seconds you can pull off the old silicone from both pieces. Reapply a fresh bead of silicone upon reinstall. Piece of cake.
@slaverace1 Just wondering, will the silicone make it hard to remove the cover later and make it tough to reinstall once there is old silicone there? Found this leak in my bike and just wanted to be sure. Thanks!
How’d you take the pipe off? Wondering how I could take off the pipe without taking off the silencer, just bought this dirtbike so I’m clueless to this stuff
You need to use a strong spring puller on the header then remove the remaining bolts, 1 bolt up top next to the engine mount and two bolts down low on the expansion chamber! Don’t over tighten the silent block bolts upon re installation as they require a certain amount of movement in them I believe! Very easy job! don’t loose the spring band on the rubber coupler!
@@slaverace1 It didn't work with me. I just managed to repair the problem with the rubber kit of the 2019 model. And to get a perfect job I had to relieve the entire right part of the crankcase to get the u-shaped sealants into the cavity
@@slaverace1 Thanks. I ordered the sealing element bottom, sealing carrier, and the right side cover gasket and plan to reseal them with the gray RTV as previously recommended. Are there any good videos on how to replace those 3 pieces? it's a '21 KTM 300 xcw with a new top end at 85 race hrs.
