Oil Pump Gear Upgrade! How To (KTM/Husqvarna/Gasgas)

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The plastic oil pump gears have been a common failure point on the Austrian 4 stroke bikes for years. Finally KTM have realised their mistake and changed out the plastic gears for some steel equivalents. But only for the final year of the generation. Luckily you can order the new steel gears and upgrade your bike!
Oil pump gear part numbers:
New steel intermediate gear: 79238006300
New steel oil pump gear: 77038001200
Old plastic intermediate gear: 79238006100
Old plastic oil pump gear: 77038001100
check parts diagrams for your specific bike to see if your bike has plastic oil pump gears.
otherwise Ive done my best to compile an exhaustive list of all the models.
models affected:
KTM: SX-F & XC-F from 2015-2022
KTM: EXC-F, XC-F & XCF-W from 2016-2022
HUSQVARNA: FC & FX FROM 2015-2022
HUSQVARNA: FE 2016-2022
GASGAS: MC-F, EX-F, EC-F 2020-2022

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Опубликовано:

28 авг 2023

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Комментарии : 94

@user-wy6gj6tu2u 3 дня назад

Best RU-vidr !

@jackkellybuilds День назад

thank you!

@user-ql6zc6sf6e 10 месяцев назад

Great video !! Just am FYI KTM 4 strokes have a great feature to lock the crank at TDC so no washers or gear jammers are necessary. While at TDC remove the large allen bolt just below the primary gear and remove the thick washer that is behind it. The end of the bolt is pointed and through the hole you will see a corresponding slot in the crank. Screw the bolt back in without the washer and this locks the crank at TDC.

@jackkellybuilds 10 месяцев назад

You're correct, it does have that feature, the reason why I didn't use to it hold the crank while I remove the bolt is that the allen screw has a tapered end on it and I was worried id shear it off with the amount of torque required to remove the bolt on the gear. It is a good feature that KTM's have though , I use it when I remove the cams to adjust the valve shims and it keeps everything in time. Thats for the comment!

@briancrumpacker 11 месяцев назад

Wow, what a great video! All the steps in order, all the way in and all the way out with no unnecessary extras. WELL DONE! Thank you!

@jackkellybuilds 11 месяцев назад

Thank you!

@jcbenson01 3 месяца назад

Video couldn’t be better. Very straight forward. 👏👏

@jackkellybuilds 3 месяца назад

Thanks mate!

@TACOMOTOCO 9 месяцев назад

Thanks for the shout out and keep up the great work you guys are doing 🤘🏽

@jackkellybuilds 9 месяцев назад

No problem Mike! I’m a big fan of your content 🍻

@valentinclavairolles 6 месяцев назад

Thanks a lot men from Belgium. Nice video and explanation !

@jackkellybuilds 6 месяцев назад

You are welcome!

@KristofSX 6 месяцев назад

great vid, thanks for that! gonna change oil pump gears on my 350 soon :)

@jackkellybuilds 6 месяцев назад

Thank you! Hopefully my video helps you get the job done easily

@jdhart111 11 месяцев назад

excellent clear video!! thank you!!

@jackkellybuilds 11 месяцев назад

Thank you!

@brycedavis907 11 месяцев назад

awesome information, thank you!

@jackkellybuilds 11 месяцев назад

Glad you enjoyed it, thanks for watching!

@stevearnol9961 8 месяцев назад

Just had my FX350 fail this gear. I wish I had seen this video before the weekend. 😅 great instructions.

@jackkellybuilds 8 месяцев назад

ah man that sucks! how bad was the damage to the engine?

@stevearnol9961 8 месяцев назад

@@jackkellybuilds waiting on that info. Cam seized in the head so not good.

@lostinpa-dadenduro7555 11 месяцев назад

I had the case off on my 2023 GasGas EX250F (unlucky rock landing 😀) and can confirm the gears were metal. A pleasant surprise.

@jackkellybuilds 11 месяцев назад

Lucky man!

@robsonenduro3316 11 месяцев назад

Nice, so I understand my new Husky fe360 2023 model is already upgraded.

@jackkellybuilds 11 месяцев назад

Yes, your bike should be fine

@350xc-f 2 месяца назад

The part number for the small gear seems to be wrong... My Ktm dealer is telling me it's and oil pump assembly for a 50sx.. Any update or corrections?

@jackkellybuilds 2 месяца назад

a quick google search would confirm it is the correct part number, maybe try another ktm dealer

@soonhooi9927 9 месяцев назад

Hi thanks for the great sharing! Any idea if these revised metal engine oil pump gears can also be used to replace the plastic ones on the LC4 engines of the 2012-2015 KTM Duke 690's?

@jackkellybuilds 9 месяцев назад

No problem! You would have to check the part numbers on those to see if they’re compatible, but I doubt it

@stmboat 11 месяцев назад

Searched and purchased both gears, shipped to my door for under 40 usd. I for one will not be torture testing the original gears any longer.

@jackkellybuilds 11 месяцев назад

sounds like a good idea! haha

@jhheintz450 10 месяцев назад

Where'd you get them? I have the steel intermediate, but still looking for the smaller steel oil pump gear. Thanks

@jackkellybuilds 10 месяцев назад

@@jhheintz450 my local ktm dealer, the part numbers are in the description

@akaminw2583 6 месяцев назад

My KTM 250 E-XCF suffered a gear failure. No oil to the top end and I had to do a full top end rebuild at 10 hours. The new part# had no issue.

@jackkellybuilds 6 месяцев назад

sorry to hear you got unlucky, at least you have the new gear now and shouldn't happen again

@akaminw2583 6 месяцев назад

Better yet, I sold that bike and I'm on a TE300i now :) @@jackkellybuilds

@isaachewett9662 11 месяцев назад

Very informative thanks jack, quick one why does your coolant look clear when dropping it?

@jackkellybuilds 11 месяцев назад

The factory coolant is a light pink colour like you see at the end, so I think in such a small volume at the start while it’s pouring out it’s hard to see the colour.

@isaachewett9662 11 месяцев назад

Ah cool thanks jack! Keep it up 👍

@jjtt2003 3 месяца назад

Great video! Question, does the 2012 350 EXC-F have the same issue needing to replace the plastic oil pump gears? Thank you so much!!!

@jackkellybuilds 2 месяца назад

I'm unsure as that motor will likely be a different generation

@justinvictoria410 2 месяца назад

So just to confirm.. my new 2024 fe350s does NOT have the plastic gear?? I watched the video anyway.. nice tutorial.

@jackkellybuilds 7 дней назад

yes the 2024's have steel gears

@johnroach873 9 месяцев назад

So will a 2020 fe250 need changing before i buy one

@jackkellybuilds 9 месяцев назад

it doesn't "need" doing, likely you may never have an issue with your plastic gears, depending how hard you ride. but if you want the added reliability of steel gears, then you might want to.

@user-is2vy7ou4d Месяц назад

Apparently it's not an issue on the 450s. Even though they have the plastic gears.

@jackkellybuilds 7 дней назад

I was under the impression the 450's have steel gears, but im not 100% sure

@showmytime9177 11 месяцев назад

do you have bearing shift arm from factory pro ?

@jackkellybuilds 10 месяцев назад

I dont think so...

@dereckrodriguez9688 3 месяца назад

Is this needed on a 2023 gas gas mc350?

@jackkellybuilds 3 месяца назад

No the 23 models already have the steel gears

@mauriciojara3581 11 месяцев назад

where can I get it

@jackkellybuilds 11 месяцев назад

your local KTM, Husqvarna or Gasgas parts dealer

@adambatchelder4121 10 месяцев назад

They have been using plastic oil pump gears for around 15 years, so has homda in there generator s really hasn't been that much of a problem

@jackkellybuilds 10 месяцев назад

It doesn't happen to every bike, but there's been plenty of cases of it happening, for the small cost of the gears themselves its a cheap way to add some reliability

@trumpforever2454 11 месяцев назад

I heard they changed it for 2020s and after for ktm 350 xcf l sure hope so because I have a 2020 and a 2022

@jackkellybuilds 11 месяцев назад

I hate to be the bearer of bad news but I just checked the parts diagrams for the 2020 and 2022 XC-F and they both have plastic oil pump gears

@tikkabrno 11 месяцев назад

@@jackkellybuilds it'd be the upgraded gear P/No ending in '100' (more fibrous plastic). Do you know if tye newer metal gear can be used in a 2021 instead of the fibrous upgraded plastic rubbish?

@jackkellybuilds 11 месяцев назад

@@tikkabrno yes the steel gear can replace either the later model plastic gear or the earlier plastic gear

@tikkabrno 11 месяцев назад

@@jackkellybuilds thank's Jack 👍 I'll be ordering one this week.

@trumpforever2454 10 месяцев назад

@@jackkellybuildsthanks for the info

@bismarcktorres8747 10 месяцев назад

Can I ask you a question about my 2018 KTM

@jackkellybuilds 10 месяцев назад

sure!

@bismarcktorres8747 10 месяцев назад

Was draining the oil and a broken C clip came out on the oil, where do you think is from?

@bismarcktorres8747 10 месяцев назад

Don’t know if that’s the right name for it but one just like the one you took off from the plastic sprocket, is it possible it could be from there or is there others inside?

@jackkellybuilds 10 месяцев назад

@@bismarcktorres8747 yeah its possible it could be from one of the oil pump gears, I would inspect to see if that's where it came from before you continue to ride it

@bismarcktorres8747 10 месяцев назад

@@jackkellybuilds if it is from that gear, do I need to take apart the clutch assembly to install a new clip? 😬 hopefully not

@mozer30 10 месяцев назад

Are you aware of the plastic oil pump failure that other models have suffered? There’s a video on here showing a failure, and how to swap to the 450f metal oil pump rotors.

@jackkellybuilds 10 месяцев назад

potentially, what other models are you referring to?

@iodineclip 10 месяцев назад

some yamaha bikes also still uses this plastic gears, which is baffling considering is a known weak point in their bikes.

@jackkellybuilds 10 месяцев назад

Im sure the engineers had their reasons at the time for the plastic gears, wether it was to save weight or save on manufacturing cost, but I think I speak for everyone when I say id prefer the reliability of steel gears in my engine than it be $10 cheaper or to save 20 grams

@sidecarbod1441 11 месяцев назад

I own a KTM enduro bike (300 2 stroke), the list of issues that I've had is 'endless'. My bike is now fully sorted and I love it, having said that I will never own another KTM and I will never recommend KTM as a bike to buy. Their customer care also sucks, many bikes have failed due to the crappy plastic gears, if the bike is one day past its warranty then KTM will just tell you to 'f-off'

@eamh2002 11 месяцев назад

This is why in making "Long Way Round" movie Charlie and Ewan got BMW bikes instead of KTM because KTM didnt think their bikes would survive or they could make it through the jorney. Good example of a good branding though cause they sell alot of KTM's with lesser quality compared to German and Japanese makers :)

@Superdisco199 27 дней назад

Which year model 300 do you own ? TPi I'm guessing?

@sidecarbod1441 27 дней назад

@@Superdisco199 Its a 2013 EXC

@WSMK-oz6ru 4 месяца назад

I believe the 690 engine still has plastic gears!

@jackkellybuilds 3 месяца назад

Fortunately the chances are low on a 690 because I wouldn’t imagine anyone getting one of those hot enough to warp the gear, but a steel gear would be a nice redundancy to have

@mrmoon1482 4 месяца назад

I got a brand new Peugeot citystar 125 scooter, paid 4k for it 2000 later this plastic gear shattered which totally destroyed the engine in a matter of seconds,

@jackkellybuilds 3 месяца назад

That’s unfortunate

@jetmuchacho 11 месяцев назад

I've got a few thousand hours on the 15+ ktms and never even heard of this. How many people have actually had one fail? My 25 year old garden tractor has a plastic camshaft gear and that piece of shit still keeps going lol. Why shouldn't this gear last as long, turning that tiny little oil pump?

@jackkellybuilds 11 месяцев назад

If you have 450's, its because they have steel gears. This issue might not happen to everyone's 250 and 350's, but there's plenty of cases of people blowing up their engine due to these gears failing. Its not the torque through the gears that's an issue, it the gears failing due to excessive heat if the bike is really being pushed

@jetmuchacho 11 месяцев назад

@@jackkellybuilds Fair enough, well if you've got it happening in your area, good on ya for letting people know. I'm just a little weary of these sort of claims that pop up often in the moto world. You can find a snake oil salesman selling dozens of parts for every make and model of bike out there, claiming the manufacturer is stupid and screwed it up, and just beaming to sell you parts turned on a lathe in some dank garage, or a cnc machine in China, to fix it... I know you're not selling anything like that here so again good on ya and hope my comment wasn't too cunty... I've been off the bike for a few weeks so.............

@stmboat 11 месяцев назад

@@jetmuchacho I get your point here. Just because they went plastic doesn't mean it was their choice. To source these gears could have cut into their profits at the time, who knows. Over-molding is always cheaper than cutting gears from solid so the theory holds up fine.

@MyKharli 11 месяцев назад

Plastic in hot oil is always a disaster .

@jackkellybuilds 11 месяцев назад

I’m sure they had their reasons initially to use plastic, but it took them too long to rectify a known issue

@sidecarbod1441 11 месяцев назад

@@jackkellybuilds Yeah, the reason is to lose weight, not much help when your engine has locked up!

@motozz8258 11 месяцев назад

@@jackkellybuilds How much do they weigh ? the fanboys always tossing on O how much do they weigh marketing , plastic bikes.

@crispincurtis8585 11 месяцев назад

Sounds like some steady business for the factory service department eh

@juanjosemunozgarcia1276 11 месяцев назад

These bike shuck

@jackkellybuilds 11 месяцев назад

🦪?

@motozz8258 11 месяцев назад

Arroant manufacturer , how many years have they been linning Mechanics bank accounts , how about the Estart probllllems run fr over 10 years . This man says thankyou ktm for metal pump gears so blidt fanboys.

@jackkellybuilds 11 месяцев назад

Say what you want about ktm, but I am definitely no fanboy, otherwise I wouldn't make this video pointing out an issue with their bikes and how to fix it with the purpose of helping others.