Whoa! KTM 790 Adventure R coolant leak fix. I was not expecting these issues.

Описание: My 2019 KTM 790 Adventure R is a great bike. This is a first production year version and has had a persistent, but small, coolant leak. Drips when the engine cooled and was left overnight. I thought I knew what was wrong and how to fix it. But I was thrown a couple of surprising curveballs. I hope you find this interesting.

Jan 2021 An update:

I'll let you review this video at your leisure but I've spoken to KTM and my dealer and the found the following:
My 2019 R came with the oval water connection flange (63535019000). Small weeping leak.
For 2020 models, KTM discontinued this and replaced with a (round) connection (63535019100). I replaced my original and found two issues. The retaining bolts bottomed out, and it leaked like a sieve!
So I ask KTM what is going on. Aha they say. You should have used shorter bolts on the second (round) flange. (My dealer did confirm that they should have pointed this out, but my washers under the original bolts were a suitable fix). Then KTM said "Oh BTW, part numbers 63535019000 and 63535019100 are both replaced with 63535019200!" (So this is the 3rd part replacement in 3 years for a piece of plastic with a hole in it....!)
KTM were very cooperative right up to the moment I asked if this was due to the all too small internal step not sealing against the thermostat. Crickets. Hmm.
Needless to say, I have ordered #...9200 on order but it's unavailable :-/: