gen1 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 4 Old 12-17-2017, 12:17 PM Thread Starter
1st Gear
Join Date: May 2017
Location: Concord, MA
Posts: 88
gen1 oil leak

I have a very tiny oil leak near the oil drain plug. It's not a cracked or a stripped drain plug, it seems to be weeping out of the two 6x30 bolts near the plug on the bottom of the case. The bolts are rusty and glistening. The amount of oil weeping out is nearly zero.

I'm wondering what I can do about this? It's probably been doing this for years but it bothers me and I don't want it to get worse.

I haven't tried to torque the bolts at all yet. I don't want to screw things up or make it worse without first consulting you guys. I've scoured the internet and I can't find any posts about this so I assume it isn't common.

Here is a picture that is not mine, but shows the two 6x30 bolts on both sides of the plug I'm talking about. It seems to be weeping out of the heads of the bolts.

What steps should I take to fix this? Anyone know the torque value for those bolts? Thanks!
JTCrow is offline  
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post #2 of 4 Old 12-17-2017, 06:11 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,498
De-Grease the bottom of your engine And DRY.
Remove the 2 bolts, are the threads oily? Does oil actually leak out of the holes? Could be porous casting.

With the bike laid on RH side, spray holes with brake or carb clean and use compressed air to dry. 3 times, we want to drive the oil back out of the porosity. Spray & dry the bolts.
Put 3 drops of Lock-Tite blue thread locker into each hole. Put a drop on the threads of each bolt. Put 1 drop Under the head of each bolt.
Install bolts and torque to 80 inch pounds. Allow to cure 30 minutes.

Now take a can of grey or white drying spray foot powder and apply 3 or 4 coats and allow to dry.
Stand the bike up. Check after 10 minutes, still dry? Start it up, check immediately and every 2 minutes.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is online now  
post #3 of 4 Old 12-17-2017, 06:28 PM
2nd Gear
Join Date: Mar 2017
Posts: 389
pdwestern's fix should work. I'd up his bid (so to speak) and I'd coat the bolts and the bores with Hylomar Sealant instead of blue lock-tite. If it's good enough for Rolls Royce it's good enough for me. After using Hylomar on my race engines I've had occasion to pull the heads (small block V8) and then successfully reuse all of the gaskets, including the Head Gasket (plus a few ft lbs torque as insurance with the Fire Ring). Not a process I'd recommend unless all other options are not available . . . but it did work and I was suitably impressed! Also used on old English motorcycles to (as much as possible) eliminate oil leaks.
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post #4 of 4 Old 12-19-2017, 03:47 PM Thread Starter
1st Gear
Join Date: May 2017
Location: Concord, MA
Posts: 88
pdwestman, Bluehighways,

Thank you so much for taking the time t help me out. I found some time today to take off the skid plate, do a close up inspection and degrease. I'll let you know how it goes.
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