Removing tappet cover

Bayside Burg · Dec 22, 2013

Hi all,
Just had the motor out of my 2005 650 to do the timing chain. Put it back together and now there is a moderate leak from the tappet cover. Is there a way to remove it and reseal it with out pulling the motor out again?
Any info apreciated.

John

bushmechanic · Dec 22, 2013

yes it worked on my 08

you could also just clean up the outside of the leak with detergent and put a dab of sikaflex 221 over it

Bayside Burg · Dec 22, 2013

Thanks mate. I will have a good look to identify if its just one spot.

Ghost · Dec 23, 2013

If you shorten the allen key it'll be easier to remove the screw next to the radiator holding the tappet cover. You will still cut yourself silly on the radiator but it's possible to remove the screw without damaging the radiator with the allen key.

regards

/Nick

makazica · Dec 23, 2013

Hello!

What do you consider to be a tappet cover, the head cover that holds the rocker arms or the two little covers through which you adjust valves?

If you are talking about the two small ones, an IKEA allen wrench that you get with furniture works great!

If you are talking about the head cover with the rocker arms, depending where the leak is, you could fix it without removing it.

M.

Bayside Burg · Dec 23, 2013

Thanks for the Reply Ghost but I am not talking about the inspection covers. I have done that and it works a treat. I am talking about the whole unit above the cylinder head. Thank you though!

bushmechanic · Dec 23, 2013

i get a thick cardboard box and cut out a rectangular section to protect the radiator fins

for sealant I use loctite 518 less mess and more effective than silicone based goop but you need to put a bit extra on out near the cam chain side .. the cover bends a lot

there was a service bulletin from KTM about using 518 on the rfs rocker cover released in 02-03

Ghost · Dec 23, 2013

Bayside Burg said:
Thanks for the Reply Ghost but I am not talking about the inspection covers. I have done that and it works a treat. I am talking about the whole unit above the cylinder head. Thank you though!

Ah that explains it. I blame language issues since english isn't my native language.

Carry on. :lol:

regards

/Nick

makazica · Dec 23, 2013

Bayside Burg said:
Thanks for the Reply Ghost but I am not talking about the inspection covers. I have done that and it works a treat. I am talking about the whole unit above the cylinder head. Thank you though!

Where does it leak?

Loctite 518 is quality stuff!

M.

Idle · Dec 23, 2013

You pulled the engine to change the timing chain?

I don't even pull the side cover, just tied the new chain to the old and jiggled it around the lower cog.

There is plenty of room to pull the valve cover in situ.

I have had good results with threebond 1211. One time I didn't even let it cure, I started and rode it after buttoning it up.

Bergini · Dec 23, 2013

Idle is still around?? i thought you fell off the big waterfall at the edge of the earth!!

Bayside Burg · Dec 23, 2013

Thanks for all the replys guys. I think it has a few leaks so may need to to the whole cover. I will have a better look after xmas

Bayside Burg · Jan 7, 2014

So I got the Loctite 518. Can the cover be removed completely or do I simply hold it and reapply? I imagine it needs to be off to get a nice clean seal. Can't wait to have it flawless again!

bushmechanic · Jan 7, 2014

take it right off scrape clean and degrease the sealing surfaces

helps to get all the oil out of the cover as well so it doesn't drip onto your sealant as you install it

put a light bead over the cam bearings and a bit extra around the cam chain tunnel

Bayside Burg · Jan 11, 2014

All done and sealed. Question though, how long does 518 take to cure?

bushmechanic · Jan 11, 2014

supposed to be instant anerobic cure to a speced film thickness

give it a couple hours though in case there is a bigger gap somewhere

Bayside Burg · Jan 12, 2014

Thanks Bushy.

Removing tappet cover

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