KLR650 oil filter cover leak

[shards]

Any of you new KLR650 owners have (or had) any issues with an oil leak from the base of the filter cover? This is the full story I posted on klr650.net :-

My 09'er weeps a little oil from the bottom of the filter cover plate. This started after the first service so I immediately suspected the shop mechanic (and there was a small mark consistent with using a screwdriver to remove the cover). Anyway, to the shop's credit, they gave me a replacement cover, with "O" ring, from another new bike on the floor. I fitted it myself but still leaks. Removed and smeared some gasket goo on the lower quandrant, still leaks.

There are definately NO marks on the engine side of the cover and the replacement cover is smooooth. "O" ring seems very tight. Have there been any issues of excessive oil pressure that might cause this?

[skidMark]

Any of you new KLR650 owners have (or had) any issues with an oil leak from the base of the filter cover? I have also posted on klr650.net if you want the full story.


Copy and paste full story.

gasket goop is your friend.

[shards]

Pasted on full story. Have used gasket goop but still leaked. Have tonight retried gasket goop and will test out tomorrow.

[Crisis management]

gasket goop is your friend.

I tend to disagree, a properly installed O-ring will seal with minimal pressure, using this stuff is simply trying to cover up a fault.

If the O-ring and groove are correctly dimensioned and the mating surface is flat it will seal, if not doesn't, take it back to the dealer and get it fixed under warranty. Bitch, moan and carry on, you paid good money for it, there is no excuse today for oil leakage.

If you are tempted to overlook the leakage and think you might be able to live with it remember how often that fiilter has to be changed and consider how much you are going to enjoy this process if you have to bog it up everytime.


Bitch & moan!

[marks]

Any of you new KLR650 owners have (or had) any issues with an oil leak from the base of the filter cover? This is the full story I posted on klr650.net :-

My 09'er weeps a little oil from the bottom of the filter cover plate. This started after the first service so I immediately suspected the shop mechanic (and there was a small mark consistent with using a screwdriver to remove the cover). Anyway, to the shop's credit, they gave me a replacement cover, with "O" ring, from another new bike on the floor. I fitted it myself but still leaks. Removed and smeared some gasket goo on the lower quandrant, still leaks.

There are definately NO marks on the engine side of the cover and the replacement cover is smooooth. "O" ring seems very tight. Have there been any issues of excessive oil pressure that might cause this?

I am a member of the order of the oily right boot.

I think the theory is that if it leaks out the oil cover it wont be in the sump to be sucked past the rings and will therefore reduce oil burning.

[pete376403]

Might be something ini that theory - Mine doesn't leak from the cover but a fair bit goes (or went) past the rings.:rolleyes:

There is a tube that fits inside the filter, and locates into a recess inside the cover. If a ham-fisted "mechanic" tried to pull the cover on using the screws when the tube wasn't properly located, it could distort the cover.

IF Motorad can get their act together (or even better, get my bike back together!)* I should have no more oil consumption issues and I'll be able to report back on the cover leakage


*bike delivered to Motorad on Monday - "should only take a day"
call on Thursday - "waiting on the barrel back from the engine reco shop, will call you tomorrow". Call them today - "should be able to collect it tomorrow"

[jezzaNZ]

Don't quote me on this but I have heard that purchasing a KTM will fix that type of leak......:Pokey:

[98tls]

As above take it back to the shop and demand a result,97 TLs leaked oil from the clutch cover,same deal cover with o-ring and Suzuki changed it the following year,may well be a design fault,whatever it is forget fixing it yourself and take it back.

[Digitdion]

Take it back to the shop and get it sorted under warranty. If you do any of it yourself that could void the warranty. Thats if they want to be fuck heads about it. And yes buying a KTM would sort it out once and for all! HAHA.

Good luck there Pete. Remember if they do not fix it properly Throw it back at them.

[shards]

Doesn't buying a KTM cause a major leak from the wallet?

You "take it back to the dealer" guys are absolutely right but....I am scared as to how long I will be without a bike, and whether it will actually get fixed anyway. This is my second (new) "O" ring.

Also my mechanic friend agrees with "crisis", a proper seating "O" ring will seal without assistance, gasket goo will probably still leak.

Hey, Marks, can I take it that yours leaks as well? Has it always?

[Digitdion]

Hay Shards, yeah you are right a big leak in the wallet. Now this is not always the case but if you pay peanuts you get monkeys! HAHA. Seriously, its a pain in the arse and you have a wee dilemma. You will do what feels right. You are right as they can take forever. I would still let them sort it while it is under warranty. Good luck either way

[marks]

Hey, Marks, can I take it that yours leaks as well? Has it always?

Only since I changed the filter (theres a moral hidden in there somewhere) - I have since removed and reinstalled it and it leaks worse. I'll try some goo

I cant be fagged hassling with the dealer (mines still under warranty)
you all know and fear the process

--- ride 50K to Welly - "yes sir its leaking - you'll have to bring it in later the week and leave it with us for a day"

"Oh sorry sir we didnt have an O ring in stock so we couldnt fix it - has to come from Assuie - can you bring it in for a day next week"

"Sir there was no need to punch me.."

[shards]

Thanks for the input guys. Love your "scenario" marks, that's probably why I won't go down the dealer route as well. I did say something on a forum thread recently (here or klr650.net, can't remember for sure) that I would "put up with sh#t if I had to" because I liked the bike so much. Well, that's come back to bite me, so now we'll see how much I like it!!

Marks, I'm going to go into Tga today (if I have time) and try and get a better-fitting "O" ring, if I find a good fit I'll get an extra for you.

Hey Pete, how did your "new" engine work out?

[pete376403]

Will let you know - they called about 10 minutes ago and said it was ready for collection.

IF the weather holds up AND I get some decent tyres fitted AND MarkS decides the planned Karapoti ride is on this Monday, thats where is will be getting it's baptism of fire. I might try the "run-it-in-like-you-stole-it" approach, because the factory method didn't really work that well last time.

With any sort of luck the new indicators were fitted as well (factory recall as some of them have been reported falling off)

[pete376403]

Only since I changed the filter (theres a moral hidden in there somewhere) - I have since removed and reinstalled it and it leaks worse. .."

I've changed the filter twice, and it would also have been done once by Motorad at the 1000k service. Doesn't leak. One filter I bought from Motorad, one bought from Supercheap. Still using the original O ring. No gasket poop of any sort used.
Only things I have noted - make sure the steel tube is started into the cover and smear the bore with a bit of oil before putting the cover on. And don't overtighten the screws, that could possibly distort the cover.

[shards]

Just to put a closure (I hope) on this - I removed the cap, got rid of all the gasket-goo-gunk, cleaned the "O" ring dry, did NOT apply grease (as suggested in the Workshop Manual), and refitted the cap by applying finger pressure patiently (as suggested by a guy on klr650.net) and then went for a ride into Mt Maunganui to get the other "O" ring. NO LEAK. Just as well, because the "O" rings in the shop would not have fit anyway. So, I have ordered up a couple of extra Kawi "O" rings because I have decided to always use a new one when changing the filter.

If it doesn't leak again after my proposed 3 day ride this week, I'll be a happy chappy.

[Crisis management]

Well done, thats the way to assemble things mechanical, carefully!

If you get a chance take the cover (with the groove in it?) to someone that specialises in O-rings (hyraulic seal supplier is good) and they will measure the groove and get you the correct O-ring.
I suspect either the groove is out of tolerance or the cover is too flimsy to guarantee a good seal, talking to an expert will provide more answers than the parts guy at the bike shop.

I've spent the morning trying to get the back end out of a KTM, so your not alone in this world of mechanical mayhem.....:2thumbsup