Gasket Sealant Recommendations - 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 13 Old 10-14-2016, 12:35 PM Thread Starter
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Gasket Sealant Recommendations

I recently installed the eagle mike doohickey and torsion spring. I have been using permatex #2 non hardening sealant for many years on automotive stuff and some motorcycles with good success, but it has failed to prevent leaking of the left side inner case of this KLR650. I spread a thin coat of it on both sides of the gasket before installing. The surfaces look good, not scratched and they cleaned up nicely. They may be slightly warped??? I don't know why it didn't seal.
I found metal gaskets sealed with red RTV when I removed the cases. Somebody else probably had the same problem ??

Anyway,
I will need to take it apart again, put in a new gasket and seal it with something that will work. I am hesitant to use RTV/Silicon where there is engine oil. Silicon has been known to break of small pieces inside the case and clog up the oil system in other bikes.

Any suggestions and/or opinions on what has worked for others or the best sealant / gasket maker to use on the left side cases would be much appreciated. Since my go-to #2 has failed me I'm left with a seemingly endless list of product options, dozens from permatex alone.
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post #2 of 13 Old 10-14-2016, 01:31 PM
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I made this mistake when I performed the doohickey upgrade:

I was finishing up at night by flashlight and was in a bit of a hurry. I somehow didn't get two bolt holes aligned with the outer gasket and instead of the bolts passing through directly into the spacer, they punched through the "dog ears" of the the gasket. I didn't catch it at first, but eventually there was quite a bit of oil spitting out of that section of gasket.

I removed the cover and installed a new gasket, this time with a thin bead of black RTV to hold the gasket in place when I installed the bolts.

Problem solved.

Could you have done something similar? Did you completely remove all traces of the former gasket from the spacer and engine block? BTW, be sure to cover up the internals of your engine if you try to sand away the gasket material. Powdery residue goes everywhere.
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post #3 of 13 Old 10-14-2016, 01:43 PM
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Best gasket sealer in the world is Honda number 4 it is gray.

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post #4 of 13 Old 10-14-2016, 01:43 PM
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Personally I use a very thin coat of RTV and had no issues. Some folks use no sealant. Also heard the Yamabond works well.

https://www.rockymountainatvmc.com/p...ube-Yamabond-4

If you want to see silicon in an engine just clean your oil screen.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #5 of 13 Old 10-14-2016, 01:46 PM
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as far as I know you can only purchase it at a Honda dealership. This stuff is amazing gasoline resistant everything resistant if it's really important this is all I use

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post #6 of 13 Old 10-14-2016, 01:50 PM Thread Starter
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subvetssn;

Thanks for the reply. I haven't pulled it apart yet to see if I misaligned the gasket. Hopefully I did make that mistake! I cleaned up the mating surfaces well. All traces of the old RTV Red sealant were gone but I'll be extra sure the next time. I really really don't want to take this thing apart more than one more time.

I'm leaning toward Hylomar sealant, or maybe an anaerobic sealant. I'm really paranoid about using too much RTV and having globs break off inside or using too little and not getting a seal.

Hylomar gets rave reviews from the Harley crowd, and I figure if it can seal up a shovelhead it can seal anything.
Anybody out there used this stuff on KLR side covers?
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post #7 of 13 Old 10-14-2016, 02:00 PM Thread Starter
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Klr4ever, Ghost Rider;

I to have read good things about the Yamaha and Honda sealers. The quick consensus seems to be that they seal very well but it's B!#@h to get the parts disassembled again, which I may have to do if my problem isn't just the sealer I'm using. Have you had this problem?

Don't see many Hondas leaking oil though.
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post #8 of 13 Old 10-14-2016, 06:04 PM
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Personally I don't use anything. But the Honda bond Yama bond are about the same can also get Japanese automotive sealant at most auto supply stores grey in color and none hardening and half the price .
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post #9 of 13 Old 10-14-2016, 07:15 PM
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Quote:
Originally Posted by beltdrive View Post
Klr4ever, Ghost Rider;

I to have read good things about the Yamaha and Honda sealers. The quick consensus seems to be that they seal very well but it's B!#@h to get the parts disassembled again, which I may have to do if my problem isn't just the sealer I'm using. Have you had this problem?

Don't see many Hondas leaking oil though.
I haven't had any sealing problems and have done a number of doohickey jobs. In all but one the old gaskets were used too.
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My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #10 of 13 Old 10-15-2016, 04:12 AM
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I bought two gaskets and didn't need either one when doing the doo
on a fairly new engine. Popped apart and right back together.

This is my son, with whom I am well pleased." ----God
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