Take note of which bolts go where so you can get them back in the correct location. This picture shows the different length bolts for the water pump cover and their position. If your careful removing the cover the gasket will usually come off in one piece and can be reused.that being said I usually like to change gaskets with a new one when removing/installing covers. Loosen the clamp on the water pump cover hose connection and remove the cover from the bike. After the coolant is drained remove the remaining three water pump cover bolts (Blue Arrows). Keep track of the copper sealing washer on the drain bolt so it doesn't get lost, also make sure it's installed upon re-assembly. Open the cap slow, otherwise you will get coolant everywhere Note: When you pull the bolt a small bit of coolant will drain then it will stop, you then have to open the radiator cap to let air into the system so that it will continue to drain. Start by draining the coolant, remove the coolant drain bolt (Red Arrow) and place a suitable catch pan under the engine (I like to use a long funnel to direct the coolant into the pan). *Screw, Water Pump Cover: 10nm (7.38 lbs ft) *Nut, Water Pump Wheel: 6nm (4.43 lbs ft) Loctite 648 *Water Pump Cover Gasket: KTM Part Number: 78035053000 KTM Part Number: 0760102455 (Note: Some people will carefully remove the seal, flip it over and re-use it without any problems.nothing wrong with that but I prefer to just change the part out since it's open). I've had a few people email me asking questions about changing the seal out so I thought I'd take some pictures this time around. My last 530's water pump seal started weeping at around 80 hrs, my current 530 just started leaking at 51 hrs. The water pump seal is installed backwards at the factory and will eventually leak, some take longer than others to do it.

You look down and notice a drip or wet trail coming from the weep hole on the water pump cover and know it's time to change the seal. A common problem with the 450-530 KTM's is a leaking/weeping water pump seal.

Instal Seal of Evil