Very fine metal in oil after Doohicky mod
This weekend I did the doohicky mod on my 2009. The inside of the case was clean and everything looked like new. After the mod, I put it all back together and and started it up. I used Kawasaki 10-40 synthetic and Kawasaki filter. I was flabbergasted at how much quieter the engine sounds after the mod - nothing but exhaust sound - never been so smooth and quiet.
Here's the rub. The oil got overfilled by almost half a quart, and it looked sort of opaque or cloudy. I didn't run it for more than a few minutes. I drained the oil (ouch - $50 in the pan) and pulled the filter. I found VERY fine metal sparkles in the oil and in the valleys of the filter. If there is visible shavings in the oil after such a short time, I'm afraid to run it until I get a chance to take it apart and check it again. I put a new filter on and new oil (Castrol Go! MC oil) and started it up. After a few minutes, I turned it off and the oil looks a little cloudy again but maybe not as bad as the first time.
We used a professional gasket remover/surface cleaner (air tool with a spinny disk sort of like brillo or something) that we used to clean the case surfaces. It throws a lot of material and cleans the gasket off nicely without messing up the surface. I think there was enough material ejected to get into the case (even though we were very careful trying not to get any in the engine) that i contaminated the oil, but the mechanic that was helping me says no way we got that much stuff in there.
The engine runs SOOOO smooth and quiet! if there is some other problem, it seems like it would sound worse, not awesome. Any ideas?
Last edited by Paul Gardner; 09-10-2017 at 11:05 PM.