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Old 1 Nov 2001
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HI I've had my 3 year old adventure for 3 weeks now and I've been realy happy with it it's perfect for riding around on the gravel roads around where I live..Love the bike
But then this morning DISASTER I was riding to work with a buddie who is running in his Tenere motor so did 40 k's at about 40-80 km/h Then when I got to the office the entire swingarm was covered in oil from the overflow...I checked my oil level yesterday and it was perfect now there is very little oil left in the motor the rest of it is all over my chain,swingarm,tyre... Has this happened to anyone !! What is the diagnosis??
What pushes up the oil pressure enough to make it pump out the breather??Head gasket..Please If you have any info mail me - link above..Thanx..I'm taking the bike up to ALfie Cox's shop this afternoon so I would appreciate some info before I go..Cheers

[This message has been edited by Grant Johnson (edited 01 November 2001).]
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Old 1 Nov 2001
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Ask here; www.offroadforen.de

They have a technical KTM forum witch is well visited.

Freek (Netherlands)

[This message has been edited by Freek (edited 01 November 2001).]
Freek (NL)
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Old 2 Nov 2001
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This sounds like a head gasket alright, although of course it may not be! Normally the only reason for oil getting pushed excessively out of the breather is increased pressure in the crankcase, usually caused by head gasket or related similar.

good luck! Hope it's not too serious. Still under warrranty?

Grant Johnson

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Old 2 Nov 2001
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NO not at all,One thing which I think it might be is the endcan on the exhaust is not standard and it has been pushing out the rivets at the base of the endcan..which to me means a blockage there...So maybe this caused an increase in pressure in the crankcase which forced the oil out..SO hopefulle it'll be as simple as repacking the pipe..Thanx for the advice gentlemen and I'll update you later today on what it was..!!
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Old 2 Nov 2001
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Just in case... here is my (humble) opinion. I don't think it is the head-gasket. A blown head-gasket does not produce overpresure in the sump, it just blows out (unless you have liquid-cooling, then you have overpresure in the cooling-system).
Overpresure in the sump is usualy coused by worn or broken piston-rings, a hole in a piston, or any other course that take's the air-presure from the above the piston to the sump (underneath the piston). There is always a certain amount of air blowing (leaking) down, that's why you have carter-ventilation. (to prevent the oil being pressed-out forcefully).
One thing you might want to check is the "oil-stopper" in the vent. (usually a bit of steel-wool). If it's missing, you blow out little drop's of oil with the execive air.

I hope this is of some help.

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Old 2 Nov 2001
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You see thats the confusing bit..There was no leak whatsoever the day before and then all of a sudden it empties out the entire oil contents in 40 kilometeres..SO that must rule out the oil stopper thingie..Shit I hope it's not the rings..The bike had a full service before I bought it and the Shop that fixed it said the compression was perfect..One thing though there was no effect on the performance of the motor what so ever it was runnning perfectly?? Confusing indeed..
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Old 4 Nov 2001
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Well gentlemen Finally it seems the problem was found..A cracked piston!!! That would explain a lot of my issues..but now raises another one or twoWhat would cause that to happen and more importantly the price.. apparantly on the 620 motor that I have the piston kit costs 4000 rand which converted to US $ is about 400 and the UK £ 290..Could someone please check on those prices in the US or Europe for me and see if that is rediculous??or if I'm getting ripped Thanx for all the help..cheers
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Old 12 Nov 2001
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well i dont know how much is a new piston for the 620 but I am sure that you can get a very good deal from USA
call this #1800 860 0686 they have the genuine parts call the number the way it is

Dino Y
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