S2R1K Oil Cooler Leak

[Goat_Herder]

In the past couple months, I started noticing a couple drops of oil underneath my S2R1K.  It would drip after each ride.  Finally, I traced it back to the oil cooler.  I don't see any damage to the cooling fins and the leak seems to be coming from the edge of the cooler, where the fold or 2 piece a metal is fused. 

Is there a fix or is it time for a replacement?  If it's replacement, what are my choices?  Suggestions welcome. 

Thanks,

[Howie]

Clean the cooler, spray with powder, run, shut off and inspect.  The oil stain in the powder will lead you to the leak. 

If you want the cooler (they are expensive, you probably do)  repaired you need a place that does aluminum radiators.  They also need to understand it must hold up to high pressure (70 PSI+).

If you do need a cooler KTM sells the same one for less.

[Buckethead]

If you do need a cooler KTM sells the same one for less.

The exact same one.

This is a pic of the bottom of the stock oil cooler from my 06 Sport 1000.



Also, be careful when removing the lines or you'll do even more damage. Those pleats are not strong at all. I recommend using liberal amounts of penetrating lubricant. Spray, let it soak for a couple of hours, spray some more, repeat for a day or so, and then go to town. Same thing at the engine case if you decide to take the lines off, unless you want to pull a piece of the engine case off with it.

[DarkStaR]

Also, you'll want to use 2 wrenches to remove or tighten the fittings.  DO NOT hold on to the cooler core when tightening or loosening the fittings.

[booger]

Also, you'll want to use 2 wrenches to remove or tighten the fittings.  DO NOT hold on to the cooler core when tightening or loosening the fittings.

Exactly, that's called using a backup wrench. A common practice for professional mechanics when dealing with delicate components like oil coolers and radiators. That's the reason there are two hexes at the fitting. One for the backup, and one for the hose.

[DarkStaR]

Exactly, that's called using a backup wrench. A common practice for professional mechanics when dealing with delicate components like oil coolers and radiators. That's the reason there are two hexes at the fitting. One for the backup, and one for the hose.

Thanks, I had no clue what it's called. I just know to do it, and why to do it.  

[Goat_Herder]

Clean the cooler, spray with powder, run, shut off and inspect.  The oil stain in the powder will lead you to the leak. 

If you want the cooler (they are expensive, you probably do)  repaired you need a place that does aluminum radiators.  They also need to understand it must hold up to high pressure (70 PSI+).

Thanks Howie.  I will give that a try.  BTW, what kind of powder do you use for this? 

[Cloner]

Thanks Howie.  I will give that a try.  BTW, what kind of powder do you use for this? 

Baby powder.  Baking soda.  Talcum powder.  Anything you can wash off later that won't stain but will darken to show you where the leak is located.

[vaclav]

I had the same exact problem on the same year/model bike when I did a track day on it. It hasn't happened on the street. I was told by people here that it couldn't/shouldn't be the cooler itself leaking. It looked to be coming from the same spot you are describing.  It hasn't happened since, so I did not do the powder thing. I will try it next time I do a track day.  Sorry - no further diagnosis.

[Goat_Herder]

Baby powder.  Baking soda.  Talcum powder.  Anything you can wash off later that won't stain but will darken to show you where the leak is located.

LOL, I thought it had to be some specialized automobile oil detective powder.  Cool beans.  When I get my bike back, I will give it a quick cleaning and throw some baby powder on it.  Thanks for the tip

[Howie]

LOL, I thought it had to be some specialized automobile oil detective powder.  Cool beans.  When I get my bike back, I will give it a quick cleaning and throw some baby powder on it.  Thanks for the tip

They do make ultraviolet dye to put in oil:
http://www.denlorstools.com/autoblog/2009/06/oil-leak-detection-use-of-uv-dye-to-pinpoint-leaks/