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January 16th, 2016, 03:51 PM   #1
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Sprocket spline stripped :( :(

I'm usually very weary of non-OEM sprockets as to not strip the spline on my bikes, but somehow a JT sprocket for KTM has done this to my bike. Frustrating, because there was no feedback or warning, just suddenly no gears and in the middle of nowhere. Got out and home now, looking at the decent job of splitting the cases

I'm no mechanic, but I'd really appreciate anyone telling me what items i'll need to do this, particularly the gaskets and the spline. At least i get to look inside my bike, but wasn't planning to do this at only 8000kms!
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January 16th, 2016, 11:26 PM   #2
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I'm about to order all gaskets and tools I need to split my engine. If you can wait a few days I can share the list as I have to look through the workshop manual and do the job on paper first to make sure I have everything before I start.
There is a complete gasket set, but that is not necessary for you so you can save some money.

For your information you will more or less take apart the whole bike.... To get the engine out you need to disassemble everything but the steering head with forks. So if you want to get started while you wait for my list you can start with that job. When you know how to do it you can do it in one hour, but it takes more time the first time.
I suggest you really pay attention to how the loom is routed, specially under and around the battery box. Take pictures. Also when you have the loom out spend some time with it and look for damaged cables and corroded connections.
Thanks from tourist and FE350
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January 16th, 2016, 11:43 PM   #3
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ordering gaskets etc

Originally Posted by jon andersson View Post
I'm about to order all gaskets and tools I need to split my engine. If you can wait a few days I can share the list as I have to look through the workshop manual and do the job on paper first to make sure I have everything before I start.
There is a complete gasket set, but that is not necessary for you so you can save some money.
Thanks for your reply. It just makes me more frustrated that the spline was sheered but no option but to split the case.

I'm very interested in ordering a complete gasket set, even if i don't need them all. Can you order two perhaps? Where are u getting the complete kit from? I had an unsuccessful search. Id be willing to order one, so if u have the link that would be cool. Also, where the hell do i get a replacement spline?
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January 17th, 2016, 12:36 AM   #4
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Google this and you will find. ktm 81730099000

There is no gasket between the engine cases, Loctite 5910 is to be used.
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January 17th, 2016, 12:55 AM   #5
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Originally Posted by jon andersson View Post
Google this and you will find. ktm 81730099000

There is no gasket between the engine cases, Loctite 5910 is to be used.
OK well 5910 is easy. But i will need a new spline and can't find it anywhere or a part number...

Happy to wait until u get a written job sheet on paper, but are you ordering the 360AUD gasket kit? That's not a bad price but is it a FULL engine gasket kit and OEM?

Still hunting spline...
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January 17th, 2016, 01:08 AM   #6
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I have one kit already home. It's a full kit and OEM. I have opened up the side cases a few times and removed the cylinder on one of my engines. But now I am about to split the cases on one.

This is a good site. It's a swedish site (store is 1 h from me) but the parts names are in english and you can find part numbers. HUSABERGSHOP.se - Reservdelskatalog - FE 570 AUS 2012 (2012)

I guess what you need is 78033010000, "COUNTERSHAFT 08"?
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Last edited by jon andersson; January 17th, 2016 at 01:12 AM.
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January 17th, 2016, 01:18 AM   #7
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nice when shop is 1hr away in the home country! I will hunt the countershaft 08 as i believe u are correct, thank you. Just have to get one to me, and then split cases. I would very much like a list of what you do on paper (or in an email or pdf)...this would help me a lot and earn the best swedish beer when i visit or our finest NZ drink if u ever come here.
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January 18th, 2016, 03:18 PM   #8
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Stay away from super hardened sprockets tham claim twice the life. They are harder than the shaft. Would rather replace a 20 dollar sprocket.
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January 18th, 2016, 03:43 PM   #9
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Originally Posted by octopusenvy View Post
nice when shop is 1hr away in the home country! I will hunt the countershaft 08 as i believe u are correct, thank you. Just have to get one to me, and then split cases. I would very much like a list of what you do on paper (or in an email or pdf)...this would help me a lot and earn the best swedish beer when i visit or our finest NZ drink if u ever come here.
If you go to the owners docs you will find good info under strip and rebuild.
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January 18th, 2016, 10:06 PM   #10
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Did you use the JT series or the MX series front sprocket ? Just so the viewers know what to stay away from. It really sucks knowing you used a great product only to have it damage another part.
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