OzVMX Forum

Marque Remarks => KTM => Topic started by: nick840 on April 30, 2015, 06:35:41 pm

Title: Ktm clutch covers 83,84,85 and 86
Post by: nick840 on April 30, 2015, 06:35:41 pm: Howdy all need some help sorting out clutch cover mystery and may even solve anyone who has issues with a leaky 84' cover

Bear with me I will probably make this clear as mud

About 4 years ago I bought what believe is a 1984 Ktm 250 mx
The fella I purchased it off was told it was jimmy Ellis bike but couldn't confirm
Now the only reason I mention this is maybe the motors not a stock one even though it's stamped 543

(http://i271.photobucket.com/albums/jj130/nickwedd/D1BC1BDD-0E09-4D6C-B0B5-EE270384F354-395-00000043E7A499DA_zpsjw9maiv4.jpg) (http://s271.photobucket.com/user/nickwedd/media/D1BC1BDD-0E09-4D6C-B0B5-EE270384F354-395-00000043E7A499DA_zpsjw9maiv4.jpg.html)

So the clutch cover had the normal rot and I paid a local bloke to mag weld and devcon and it came up ok but I was throwing some money at this steed and still wasn't comfortable with potential problem

(http://i271.photobucket.com/albums/jj130/nickwedd/C16BAD80-82B8-45A7-8301-723BF7373961-395-000000443D637501_zpscikrezvz.jpg) (http://s271.photobucket.com/user/nickwedd/media/C16BAD80-82B8-45A7-8301-723BF7373961-395-000000443D637501_zpscikrezvz.jpg.html)

(http://i271.photobucket.com/albums/jj130/nickwedd/560503DE-137D-465F-B826-D5F59CABD393-395-0000004433F1B355_zps0dvoshqz.jpg) (http://s271.photobucket.com/user/nickwedd/media/560503DE-137D-465F-B826-D5F59CABD393-395-0000004433F1B355_zps0dvoshqz.jpg.html)

Now the fella I bought it off found another cover and I paid extra for it cos "there rare as hens teeth"

But it didn't fit the water pump is a lot wider and some searching found out it was for a 86

(http://i271.photobucket.com/albums/jj130/nickwedd/3A68DA2C-EC21-4D5B-AB00-F1575587E91E-395-000000442887936C_zpsvfuggli6.jpg) (http://s271.photobucket.com/user/nickwedd/media/3A68DA2C-EC21-4D5B-AB00-F1575587E91E-395-000000442887936C_zpsvfuggli6.jpg.html)

(http://i271.photobucket.com/albums/jj130/nickwedd/462593B3-E5E7-4D01-8214-B1E32E750276-395-0000004414412F66_zpscqywky14.jpg) (http://s271.photobucket.com/user/nickwedd/media/462593B3-E5E7-4D01-8214-B1E32E750276-395-0000004414412F66_zpscqywky14.jpg.html)

About a year off computer searching and realising it's an issue a bike came up for sale on gumtree in Victoria and looked like the same cover but a later model bike but cover was in much nicer condition than mine and I could tell from photos the water pump was similar size
I rang the fella and said I will pay for the whole bike just send me the cover as another whole bike in the house wasn't worth the argument
So it's the same as this

(http://i271.photobucket.com/albums/jj130/nickwedd/CF7164E3-0DDB-471A-8654-B97E91D03BC5-395-0000004407353FE7_zpsf1ekvxcm.jpg) (http://s271.photobucket.com/user/nickwedd/media/CF7164E3-0DDB-471A-8654-B97E91D03BC5-395-0000004407353FE7_zpsf1ekvxcm.jpg.html)

(http://i271.photobucket.com/albums/jj130/nickwedd/C1DA4153-E99A-4FC2-A930-C929286DAC09-395-00000043FD333043_zpspz0pgotv.jpg) (http://s271.photobucket.com/user/nickwedd/media/C1DA4153-E99A-4FC2-A930-C929286DAC09-395-00000043FD333043_zpspz0pgotv.jpg.html)
Title: Re: Ktm clutch covers 83,84,85 and 86
Post by: nick840 on April 30, 2015, 06:42:07 pm: Now the thing about the cover it is aluminium and it fit the 84 what a relief

Here's what I just took another aluminium one off

(http://i271.photobucket.com/albums/jj130/nickwedd/9867C839-A1F8-4CC9-9C01-026F9E511774-395-00000043C7A386E6_zps4ngcwvjm.jpg) (http://s271.photobucket.com/user/nickwedd/media/9867C839-A1F8-4CC9-9C01-026F9E511774-395-00000043C7A386E6_zps4ngcwvjm.jpg.html)

So anyone know why the two 544 covers are different ?

Here's a pic show different water pump width (same part number)

(http://i271.photobucket.com/albums/jj130/nickwedd/983BFC6E-4C27-467E-B110-999852DD1B83-395-00000043F30134A8_zpsy22fdxmq.jpg) (http://s271.photobucket.com/user/nickwedd/media/983BFC6E-4C27-467E-B110-999852DD1B83-395-00000043F30134A8_zpsy22fdxmq.jpg.html)

Cheers nick
Title: Re: Ktm clutch covers 83,84,85 and 86
Post by: gra1961 on May 01, 2015, 08:05:29 am: i have a few 543 and 544 motors only one has the wider cover.the crank is longer on that side and has a slot in the end that drives the seperate water pump drive shaft and the wider cover also has a bearing in it next to the seal.also one of the motors i have has the aluminium narrow type water pump cover.the rest are all corroded mag type.
Title: Re: Ktm clutch covers 83,84,85 and 86
Post by: gra1961 on May 01, 2015, 08:13:03 am: by the way the 500's have the 2 different width water pump hsgs as well.
Title: Re: Ktm clutch covers 83,84,85 and 86
Post by: nick840 on May 01, 2015, 02:38:25 pm: Thanks for the info mate

Do you know if your 544 aluminum cover fits your 533 motor?
Title: Re: Ktm clutch covers 83,84,85 and 86
Post by: gra1961 on May 02, 2015, 06:39:09 am: yes they fit but you have to match the water pump drive on the crank to the hsg.ie wide water pump hsg has to have slotted end drive on the crank.