np241c leak with pics

[Outnumbered]

Just picked up this 90 last week with all stock drive train and 140k. Tcase had been leaking and spraying ATF all under the truck, and I knew when I bought it. PO gave me receipt for shop replacing seal at slip yoke last month so I figured ATF was from before fix. Well, I check fluid level and its damn near empty. I put 2 qts ATF in it and then drove it about 10 miles and when I get home its leaking badly. It was not leaking like this until I put the ATF in.

So, two questions:

1) Since it appears the PO had run this thing dry, is it even worth re-sealing? There is no bad vibe or groan from the tcase.

2) This leak does not look like it is from the slip yoke seal. Any common leak-prone seals I should look into based on these pics? These were all taken from the driver side looking up.

Thanks in advance for the help

(edit, cant post pics i guess)

 

[Outnumbered]

 

[Outnumbered]

Looks to be leaking from the top of the tail housing. It only leaked after I filled it up with 2 qts of ATF. Any thoughts?

 

[ChrisPerry]

Clean the crap out of it. Let it dry completely. Needs to be clean to see what needs sealing.

 

[nutt7]

x2 That's how I recently learned that my case had a crack in it (couldn't find my leak anywhere!) After cleaning, I saw a few lines and ATF would seep out after an hour or so. Patched it up, all is well. Most cracks happen in the front, so I doubt that is the case for you...

 

[plyr2k]

Looks to be leaking from the top of the tail housing. It only leaked after I filled it up with 2 qts of ATF. Any thoughts?

The TOP of the tailhousing would need one hell of a gap to throw fluid like that. Looks like the slip yoke to me. When things get spinning its amazing where fluid will end up.

And X2 on cleaning on it.

 

[Outnumbered]

Thanks. One other thing I discovered after I bought it is that it threw the rear drive shaft. Found a tell-tail dent that looks recent and it looks like the rear u-joint let go. May be a good cause of a cracked tail housing

 

[ktmoutfront]

I put a longer hose on the vent. Put 10 psi into it and the leak was obvious. Cracked front housing.

 

[Outnumbered]

I put a longer hose on the vent. Put 10 psi into it and the leak was obvious. Cracked front housing.

That's a great idea, thanks.

Fellow KTM rider, can always count on them

 

[Outnumbered]

I put a longer hose on the vent. Put 10 psi into it and the leak was obvious. Cracked front housing.

Any idea what caused it?

 

[ktmoutfront]

Too much air time. Or landing from too much air time. Cracked the case at the casting seam. TIG welded it up and was good to go.

I don't ride a KTM anymore. "With age you get a cage". But the name stuck.

 

[Kocher93]

Looks like mine my slip yoke is all worn weird and is leaking. Ha ktms, they're nice but they're no CR500s

 

[ktmoutfront]

My 525xc would smoke my cr 500 after 100 feet in a sand wash any day. We tried. Of course the 525xc was not stock and the suspension was many times better than the 500. 2 different bikes made for 2 different things. Loved riding both of them.

 

[Outnumbered]

My 525xc would smoke my cr 500 after 100 feet in a sand wash any day. We tried. Of course the 525xc was not stock and the suspension was many times better than the 500. 2 different bikes made for 2 different things. Loved riding both of them.

You nailed it there

 

[Kocher93]

lol My 500 will always be my favorite bike, power everywhere. My old mans got a 92 620 he throws around and i got a 84 504 rotax thats a tractor, best trail bike ever. Plus riding an old 500 with no type of rubber between the bars and the bike KILLS my hands

 

[chulisohombre]

Looks to be cracked or worn tail housing to me as well. Got yo clean it and then see whats up. I. miss my yz465. That sucker was fast but sucked gas like a two dollar whore. Downgraded to a rm250 and its still fun but not nearly as fast. Can't wait for summer.

 

[Outnumbered]

Forgot to update this thread. Ended up being a cracked speedo housing. Bought a used t-case and swapped housings (this year is near impossible to find a speedo housing for). This fixed one leak but then discovered that the slip yoke was also leaking, even after a new bushing and seal. So, had the drive-shaft rebuilt with a new slip yoke and now its tight--no leaks.

Thanks for the help.

 

[Big Ray]

...just picked up a vss speedo housing with sensor for $30 on fleabay about 6 weeks ago...