Case oil leak - 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 7 Old 02-03-2020, 12:18 AM Thread Starter
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Case oil leak

Hi guy's, I have developed a oil leak in the case coming out of the threads from one of the bolts that hold the two halves together, the particular bolt is the one directly behind the water pump, has anyone else seen this issue?

I was thinking of going in and pulling the bolt and putting some tread locker on it and seeing if that stops the weeping.

Regards,
Kent

2009 KLR650: Front Suspension: Intiminator & Progressive W/Amsoil 5wt, Spring preload adj, Rear Suspension: Progressive 465 RAP, Electrical: Mosfet R/R, Flashing LED brake light.Body: SW Motech crash bars, skid plate & Foot pegs, Shinko 705's, Kaoko throttle lock, Engine: Rotella T6 5W/40, KLX Needle, LEXX muffler, EM Doo & torsion spring, Thermo-Bob 2, exhaust cam advanced 7.5deg, Brakes: Warp 9 320mm brake kit and Clutch brake levers, Ceramic pads, Braided stainless brake lines.
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post #2 of 7 Old 02-03-2020, 03:34 AM
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Make 100% sure the source of the leak isn't coming from the water pump weep hole. That would be my first guess and then it would be time to replace the seals in there.
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post #3 of 7 Old 02-03-2020, 05:55 PM
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Originally Posted by vfrkent View Post
Hi guy's, I have developed a oil leak in the case coming out of the threads from one of the bolts that hold the two halves together, the particular bolt is the one directly behind the water pump, has anyone else seen this issue?

I was thinking of going in and pulling the bolt and putting some tread locker on it and seeing if that stops the weeping.

Regards,
Kent
"one of the bolts that hold the two halves together"?? Are you referring to the center seam of the engine? Bolt heads are on the LH side of the bike?
You could degrease, dry & try some Loc-tite blue. Snug to about 70-80 INCH Pounds on all those small bolts.


"behind the water pump"?? Do you mean holding Clutch Cover on?

Bolt at 3:00, try some Loc-tite blue, on the threads & under the head.

Bolt at 6:00, Refer to JT Crow's post.

pdwestman
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post #4 of 7 Old 02-03-2020, 09:31 PM Thread Starter
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Sorry about the confusion, the bolt that is leaking is one of the bolts that holds the two case halves together, the threads where the leak is coming from are located looking from the front of the bike back at the engine on the left side to the right of the water pump, yes I think that pulling the left side stator cover off I should be able to access the bolt and pull it out and lock tight the bolt and tighten to spec.

Regards,
Kent

2009 KLR650: Front Suspension: Intiminator & Progressive W/Amsoil 5wt, Spring preload adj, Rear Suspension: Progressive 465 RAP, Electrical: Mosfet R/R, Flashing LED brake light.Body: SW Motech crash bars, skid plate & Foot pegs, Shinko 705's, Kaoko throttle lock, Engine: Rotella T6 5W/40, KLX Needle, LEXX muffler, EM Doo & torsion spring, Thermo-Bob 2, exhaust cam advanced 7.5deg, Brakes: Warp 9 320mm brake kit and Clutch brake levers, Ceramic pads, Braided stainless brake lines.
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post #5 of 7 Old 02-04-2020, 12:18 PM
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Originally Posted by vfrkent View Post
Sorry about the confusion, the bolt that is leaking is one of the bolts that holds the two case halves together, the threads where the leak is coming from are located looking from the front of the bike back at the engine on the left side to the right of the water pump, yes I think that pulling the left side stator cover off I should be able to access the bolt and pull it out and lock tight the bolt and tighten to spec.

Regards,
Kent
Hummmmmm!

There is no reason yet to pull the stator cover off. Use brake cleaner & compressed air to back flush and dry the threads in place. Then use Penetrating Grade or Wick-n-Loc thread sealant.

My engine has had a slight 'weep' from the upper center seam, under & behind the starter motor, for about 30 years.
I spray it down with Engine Degreaser & hot water, once or twice a year.
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pdwestman
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post #6 of 7 Old 02-04-2020, 12:38 PM
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Hummmmmm!

There is no reason yet to pull the stator cover off. Use brake cleaner & compressed air to back flush and dry the threads in place. Then use Penetrating Grade or Wick-n-Loc thread sealant.

My engine has had a slight 'weep' from the upper center seam, under & behind the starter motor, for about 30 years.
I spray it down with Engine Degreaser & hot water, once or twice a year.
I had a leak in the case under the engine from what I thought was weeping from one of the bolts near the oil plug. I thought it was a bad case mold or something like that but it ended up being oil from the upper oil plug there near the water pump, the one below the oil filter housing. That plug had rusted up a bit and the rubber gasket must have gone bad. It was an incredibly slow, almost imperceptible weep, but that oil was finding its way down to the lowest point, which is that bolt at the seam under the engine. Replaced the gasket and bolt and no more leak. That was a strange one.

Moral of the story is if you have one of these leaks, its a good idea to clean everything and baby powder the area to confirm where it's really coming from. You may be as surprised as I was!
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post #7 of 7 Old 02-04-2020, 04:10 PM
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Quote:
Originally Posted by pdwestman View Post
...
My engine has had a slight 'weep' from the upper center seam, under & behind the starter motor, for about 30 years.
I spray it down with Engine Degreaser & hot water, once or twice a year.
Mine developed a bit of a weep coming from the front of the cam chain tunnel, right where the bolt goes through the gasket (the one that is supposed to ensure it doesn't leak there).

I find it very annoying. Every once in awhile I throw a handful of dirt at it. The dirt that sticks to the oil matches pretty well to the rest of the dirt. ;^)

Tom [email protected]

“I decided I could lose nothing by the soft approach. If that didn't produce for me—and I didn't think it would—nature could take its course and we could bust up the furniture.” -Philip Marlowe

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