Oil leaks - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 12 Old 04-19-2017, 12:04 PM Thread Starter
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Oil leaks

I have been plagued with oil leaks since installing an oversized piston. The first one was the stator cover gasket on the left side engine cover. Fixed it with a new gasket. The second one was the valve cover gasket. The bolt was striped and wouldn't tighten down. Fixed it with a new thread insert. However, there appeared to be a third one which I couldn't find. So, I tried the trick of spraying Gold Bond foot powder on the engine and quickly found it. It appears the gasket on the cover behind the stator cover is weeping oil from the top part of the cover. I never had this particular cover off so am not sure why the gasket should be leaking. Is there some fix for this other than removing the over and replacing the gasket?
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post #2 of 12 Old 04-19-2017, 01:59 PM
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Sounds like your crankcase venting is plugged in some way.
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post #3 of 12 Old 04-19-2017, 03:15 PM Thread Starter
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So, I hate taking things apart until I have at least a vague idea about what I am doing. I assume that black house going from the top of the crank case to the air box is the crank case vent. How would it get plugged? Should I just take the hose off at the air box and see if I can blow through it? I believe my bike, a 2009, has the required Calif. pollution mods. Would this be part of the problem?

Last edited by madmotorcyclist; 04-19-2017 at 03:32 PM. Reason: additional info
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post #4 of 12 Old 04-19-2017, 06:23 PM
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Did you purchase this bike used?

Any chance that someone installed an automotive PCV valve into the crankcase breather hose, UP-side Down? That could cause a pressure build up.

Stock and standard vent system (just an open hose between nipples) works best on this large single cylinder engine.

The hole going into the air box by the top shock mount is only about 3/16-1/4 inch, if I remember correctly and does have a little foam filter stuffed into the nipple from the Inside! Don't blow it out with compressed air, use your mouth to check flow.

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post #5 of 12 Old 04-19-2017, 08:49 PM Thread Starter
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I purchased the bike new so I'm sure it does not have a pct valve.
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post #6 of 12 Old 04-19-2017, 09:43 PM
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Quote:
Originally Posted by madmotorcyclist View Post
I have been plagued with oil leaks since installing an oversized piston. The first one was the stator cover gasket on the left side engine cover. Fixed it with a new gasket. The second one was the valve cover gasket. The bolt was striped and wouldn't tighten down. Fixed it with a new thread insert. However, there appeared to be a third one which I couldn't find. So, I tried the trick of spraying Gold Bond foot powder on the engine and quickly found it. It appears the gasket on the cover behind the stator cover is weeping oil from the top part of the cover. I never had this particular cover off so am not sure why the gasket should be leaking. Is there some fix for this other than removing the over and replacing the gasket?
I have a 2012 KLR 650 with 4700 miles on it doing my first oil change on it by myself. What oil is recommended? It's getting heated quite quickly. Any pointers are appreciated ASAP please and thank you.
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post #7 of 12 Old 04-20-2017, 09:35 AM
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Originally Posted by Famous00 View Post
I have a 2012 KLR 650 with 4700 miles on it doing my first oil change on it by myself. What oil is recommended? It's getting heated quite quickly. Any pointers are appreciated ASAP please and thank you.
Famous00,
I highly recommend the Kawasaki 10W40 Motorcycle oil, Part # K61021-202A. As you can read about in this thread,
Laboratory Oil Analysis Thread! , left click on the blue hi-lite.

Go to the top upper area of screen and use the drop-down menu of forums, active topics and such.

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post #8 of 12 Old 04-20-2017, 12:08 PM
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I found the source of your oil leak, sorry.

alternator starter clutch assembly

pdwestman
Modify at "YOUR OWN RISK"!

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post #9 of 12 Old 04-20-2017, 01:56 PM Thread Starter
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I blew into the crankcase vent hose. From the bottom into the airbox all was clear and easy to blow into. So, when I blow from the top into the crankcase it is slightly harder, but really not much. When I blow lightly, I can feel air coming out from the gasket where it is leaking oil. It is the top of the second one of those two gaskets on the left side that gives you access to the doohickey spring, etc. I'm considering two options. The first one is to replace the gasket, which would actually require replacing both gaskets to the tune of $40. The second option I am thinking about trying first is to simply coat the housing in the area where the leak is occurring with silicon and see if it will keep the oil in. Any suggestions?
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post #10 of 12 Old 04-20-2017, 04:14 PM
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Degrease with Brake cleaner or Carb cleaner. Silicone sealant might work. Automotive Goop or Shoe Goo may be stronger.

Permatex Cold Weld epoxy or JB Weld epoxy has worked on leaky center seams for me. Doesn't have to be a very heavy/thick coat. It will chip loose if ever the need be.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1.
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