Not your normal oil leak...

At least I don't think it's normal for a leak through the case! When I first bought my 08 SD a few months back I noticed a little dark oil beneath it once in a while after riding. I assumed it was just blowout from the vent tube. Well, I did my 1st oil change last weekend (how much fun was that...only took me 2 hours!). It was then that I noticed the oil leak was clean oil so...not from the vent tube. Well, I fired it up and got on my back...to my suprise I found a small pin-hole in the actual case on the bottom as you can see from the pics. Warranty item and being handled by my local dealer. Probably just replacing the actual half case. First I've ever seen of a case leak. Don't know if its common or not but my buddy JLowrance tells me it could be from the sand casting process.



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Couldn't believe it until I saw it. Bob said it was a pinhole and was leaking oil. I was sure the oil was migrating from somewhere else.

As he said, climbed under bike, fired it up and sure enough oil passing right throught the cases. Obviously caused by a casting imperfection during sand casting process. An air bubble didn't make it all the way to the riser in the mold, got stuck and didn't get caught in the inspection (or lack thereof) process. Obviously KTM do not radiographically inspect each casting but they should of at least dye penetrant inspected each one but somehow this defect got through.

Unfortunately it's located in the actual engine cases (not side case) so not and easy fix. They'll either R&R motor, split cases and rebuild with new cases or hopefully just replace motor. Another possibility is grinding out defect and weld repairing it.

I'm sure everyone will be waiting with baited breath Bob.

Good luck Bob. Hopefully they get it sorted properly.

John

Well, I decided to take the safe route and get the problem documented wiht KTM. I called the customer care line and talked to a rep who wrote up a case. He will call my dealer who is doing the repair work. I take the bike to the dealer for the initial inspection tomorrow. Since it's only a pinhole leak I will keep the bike until they decide how to fix it. More than likely it will be a new case for the bike. Yes, I could just slap some JB on there but I'd rather get the thing taken care of with proper documention and history. I can live w/o the bike for a few days...almost!