Doohicky replacement; Now oil leak - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 14 Old 11-06-2015, 08:46 PM Thread Starter
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Doohicky replacement; Now oil leak

So full disclosure, I'm not much of a mechanic....but I'm learning. I recently purchased a 2006 Klr and have read about the infamous doohickey. I figured since I ride the mountains in south central Pa and often don't have cell reception and often ride alone, swapping the doohickey would be a good move.

I did the upgrade today. All seemed to go well, but I noticed after a test ride that I've got oil leaking out from around the bolts of the case. I didn't have a torque wrench to tighten the bolts to spec, but I'm pretty sure their cinched down pretty well.

What could be the cause of this?
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post #2 of 14 Old 11-06-2015, 10:00 PM
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Did you replace the gasket? A dirty surface is the only thing that would allow oil to pass. If it is a new gasket it could be torn, or not properly in place. Can you tell if it is the inner or outer? Hopefully just the outer is leaking. Some folks like to use silicone but I tend just to wet the gasket with oil to help give it a decent stick.
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post #3 of 14 Old 11-07-2015, 09:17 AM
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You say "leaking out from around the bolts". Is that all the bolts or just a couple? If it's around all the bolts likely thye are not tight enough. But you have to be careful here. Without a proper torque wrnech it's easy to strip out the casing and they you have a bigger problem. In my experience folks who don't do much mechanical work tend to tighten things too much.

If you didn't replace the gasket that is probably the problem and you should head that direction. Gzood on you to attempt the doo replacement. How did you torque the rotor bolt?

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post #4 of 14 Old 11-07-2015, 12:19 PM
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Quote:
Originally Posted by klr4evr View Post
You say "leaking out from around the bolts". Is that all the bolts or just a couple? If it's around all the bolts likely thye are not tight enough. But you have to be careful here. Without a proper torque wrnech it's easy to strip out the casing and they you have a bigger problem. In my experience folks who don't do much mechanical work tend to tighten things too much.

If you didn't replace the gasket that is probably the problem and you should head that direction. Gzood on you to attempt the doo replacement. How did you torque the rotor bolt?
Gaskets is the first thing that came to my mind, too. Did you reuse the old one? And where are you in PA? My folks live in Carlisle - some of our members live in your neck of the woods, too.

The more info (and pics) you can supply, the better.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

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Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
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post #5 of 14 Old 11-07-2015, 02:10 PM
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I've seen instances of TOO Much silicone sealant IN the bolt holes.
It creates "Hydraulic Lock", the bolts may be tight, but the cover may be Loose!
DO Not try to tighten more at this point! It would either break-out the casting or strip the threads!
Take each bolt Out and clean out the excess sealant if needed.

I'm Not Saying that this happened. I only suggest it is possible.
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post #6 of 14 Old 11-07-2015, 03:04 PM Thread Starter
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Thanks for the help guys. I think I've got it figured out.

As it turns out, while I had replaced the gaskets with new ones, I didn't have it centered properly and wrenched one of the bolts right through the gasket causing it to tear.

I removed the cover and replaced the gasket again with one that wasn't torn...but still had the leak. So I tore the bike down AGAIN.

After inspection, I realized that I didn't seat the wiring that comes out of the right hand side by the shift lever properly. That was my leak!

To answer one of your comments, I used an Eagle Mike kit that included a wrench for the rotor bolt. I'm a pretty strong guy, about 210lbs and in the gym regularly, and it took me a good 30minutes to get that freaking bolt off. I thought I was going to tear my arm off.

Thanks again for the help. This forum is an incredible help for newbies like myself who want to learn how to work on these bikes themselves.
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post #7 of 14 Old 11-07-2015, 03:06 PM Thread Starter
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I'm from Chambersburg. I'm about 30 miles south of Carlisle. Would love to meet up with some other riders. As I mentioned, I pretty much go it alone most of the time. While I enjoy that sometimes, it always is nice to know others that ride as well.
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post #8 of 14 Old 11-07-2015, 08:55 PM
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Glad you got it figured out. Yeah, gotta be just so careful with these things.

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post #9 of 14 Old 11-08-2015, 02:10 PM
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I'm still not understanding how you set the correct torque on the rotor bolt?

It is a torque to yield fastener which is why replacement is recommended so torque (bolt tension) is more critical than for standard bolt applications. Looser or tighter are not ideal as both can result in failure.



Quote:
Originally Posted by Jerrshoe View Post
Thanks for the help guys. I think I've got it figured out.

As it turns out, while I had replaced the gaskets with new ones, I didn't have it centered properly and wrenched one of the bolts right through the gasket causing it to tear.

I removed the cover and replaced the gasket again with one that wasn't torn...but still had the leak. So I tore the bike down AGAIN.

After inspection, I realized that I didn't seat the wiring that comes out of the right hand side by the shift lever properly. That was my leak!

To answer one of your comments, I used an Eagle Mike kit that included a wrench for the rotor bolt. I'm a pretty strong guy, about 210lbs and in the gym regularly, and it took me a good 30minutes to get that freaking bolt off. I thought I was going to tear my arm off.

Thanks again for the help. This forum is an incredible help for newbies like myself who want to learn how to work on these bikes themselves.
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post #10 of 14 Old 11-08-2015, 03:41 PM
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Quote:
Originally Posted by Jerrshoe View Post
I'm from Chambersburg. I'm about 30 miles south of Carlisle. Would love to meet up with some other riders. As I mentioned, I pretty much go it alone most of the time. While I enjoy that sometimes, it always is nice to know others that ride as well.
I know that area pretty well. Unfortunately, my Dad rides bicycles. He gave up MC's a long time ago. I haven't been out east in a while. And when I do go, I pretty much do nothing but eat and fish.

There are some riders out there, though. If you are looking for riding buddies, start a new thread.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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