Smoke on startup - Page 2 - 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 #11 of 45 Old 09-26-2019, 12:04 PM Thread Starter
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5 more posts and I can post pics of what I found. For now, I'll try and describe.
Oil collecting on the bottom of the coolant hose (which is above the exhaust connection).
Oil on the bottom half of the exhaust bracket (that connects the exhaust pipe to the head.
And, under/behind the exhaust bracket where the exhaust bracket butts up against the head, there's a rectangular cutout that, almost looks like it's supposed to be that way but for the corner of the rectangular cutout is broken off. I need to find another KLR and look and see if it too has a rectangular cutout in the head connection under/behind the exhaust bracket. It looks like this could be where the oil is coming out: but why would oil be coming out of the exhaust port?

Last edited by Schoen; 09-26-2019 at 04:44 PM.
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post #12 of 45 Old 09-26-2019, 12:56 PM Thread Starter
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Made it to 15 posts, uploaded pics, just waiting (I guess) for that to take, and then I'll post 'em. Going to swing by the local bike shop and see if there's a KLR there so I can look at the exhaust connection. Thanks for your patience and help with this.
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post #13 of 45 Old 09-26-2019, 02:19 PM
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The rectangular open area is common to all KLR650 heads. The shiny corners are from the milling machine surfacing the head gasket area and those corners 'hang-down'.

pdwestman
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post #14 of 45 Old 09-26-2019, 03:28 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
The rectangular open area is common to all KLR650 heads. The shiny corners are from the milling machine surfacing the head gasket area and those corners 'hang-down'.
Yep, discovered that at the bike shop where they still have a few KLRs to look at.
And just got my pics uploaded so I'll get them into this thread now.

Last edited by Schoen; 09-26-2019 at 04:46 PM.
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post #15 of 45 Old 09-26-2019, 03:37 PM Thread Starter
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First Pic: oil collecting on the underside of the coolant hose, just above and to the left of the exhaust connection (probably running down to the left because of the bike resting on the kick stand). This is fresh oil.

Second Pic: oil on the underside of the exhaust bracket.

Third Pic: under and behind the exhaust bracket. Arrow pointing to the rectangular cutout (which I've since learned is meant to be there) which has a broken off corner, partly visible.

Will spend some more time tonight to see if I can pinpoint where the oil is coming from. Didn't have a whole lot of time when I was taking these pics and was not dressed appropriately for foraging.
Attached Images
File Type: jpg Coolant Hose - oil on underside.jpg (93.6 KB, 10 views)
File Type: jpg Exhaust bracket - oil on bottom half.jpg (87.6 KB, 11 views)
File Type: jpg Exhaust connection to head - underside.jpg (77.8 KB, 16 views)

Last edited by Schoen; 09-26-2019 at 04:47 PM.
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post #16 of 45 Old 09-26-2019, 04:29 PM
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Quote:
Originally Posted by Schoen View Post
First Pic: oil collecting on the underside of the coolant hose, just above and to the left of the exhaust connection (probably running down to the left because of the bike resting on the kick stand). This is fresh oil.
Second Pic: oil on the underside of the exhaust bracket.
Third Pic: under and behind the exhaust bracket. Arrow pointing to the rectangular cutout (which I've since learned is meant to be there) which has a broken off corner, partly visible.
Will spend some more time tonight to see if I can pinpoint where the oil is coming from. Didn't have a whole lot of time when I was taking these pics and was not dressed appropriately for foraging.
Can you follow the oil trail up from the exhaust flange to the joint between the head and the valve cover? My first guess is that there is a valve cover gasket leak directly above the exhaust pipe connection at the head. For a closer inspection of the valve cover gasket you may need to remove the gas tank.

Perhaps you've already done this? If not, you should consider doing it now.

Jason
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post #17 of 45 Old 09-26-2019, 04:47 PM
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Once the fuel tank is removed, the source may be quickly spotted. I'll guess the RH forward valve cover mounting bolt & its rubber gasket.

Even if the source is readily found, plug the fuel hose & fuel tap vacuum hose and using a degreasing product (like Gunk Engine Brite) and water to rinse (Hot water if you can), proceed to thoroughly degrease & de-mud the entire bike. Especially the top of the engine & around the spark plug. There is spark plug well drain hole below the thermostat housing, use a wire or even a drill bit to clean it out.

With a thoroughly clean & DRY engine, if necessary one can spray a white or gray drying Cheap Foot Powder around the suspect area. It will stain very quickly upon start up to show leakage area.

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post #18 of 45 Old 09-27-2019, 12:13 AM
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That head/valve cover seal is a big thick rubber gasket and there is not much pressure under the cover because it is vented to the crankcase which is vented to the clean air box. So, not much pressure is required from those four head cover bolts to seal that big rubber gasket. No sealant is necessary. Just make sure the surfaces on the head and the cover are clean as well as the area under the rubber seals on the four special bolts. Lightly snugged by hand feel is fine to make a good seal and not risk striping the threads in the head.

If you find stripped threads in the head for one of those bolts, it is easy to drill, tap and install a helicoil for the stock bolt. I did it using borrowed tools in a small motorcycle in Thunder Bay, Ontario on the way from Houston to Alaska. It was the mechanic's day off. I have no idea why it popped halfway to Alaska but, since I am the only guy who works on my bikes, it must have been my fault.

Last edited by GoMotor; 09-27-2019 at 12:20 AM.
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post #19 of 45 Old 09-28-2019, 05:08 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
Once the fuel tank is removed, the source may be quickly spotted. I'll guess the RH forward valve cover mounting bolt & its rubber gasket...
Yep, that's the one. I can even turn it a little bit with my fingers. Now I guess I find out if it's just the female threads that are stripped, or if he actually broke the internal stud the bolt screws into. You can see all the silicone glue he put around the gasket edge trying to keep the oil in.
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File Type: jpg source of oil leak.jpg (101.4 KB, 11 views)

Last edited by Schoen; 09-28-2019 at 06:18 PM.
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post #20 of 45 Old 09-28-2019, 05:30 PM Thread Starter
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Well, there you go.
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File Type: jpg broken valve cover bolt.jpg (81.8 KB, 11 views)
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