UH OH My bike is spewing oil....help!

[IndyKTM]

First thing I should say is that my bike is pretty much stock. I have done the little clip/carb mod and went one tooth down on the countershaft sprocket though, but that's it.
Went riding the other day and when I pulled into the house I smelled burning oil. There was oil all down the right side of the bike covering the pipe, the battery cover, the swingarm, my pants, and a little on the case cover. I checked the oil level and it was down a lot, about a quart. So I assume this had been happening for a while. I cleaned the bike and refilled the oil, then fired it up. Immediately I saw that oil was quickly leaking/pooling from a very small area just above the oil filter location and below the forward head bolt on the right side of the engine. It was coming from where the case and the outer cover meet...it was coming from what looks like a tiny gap in the seal. Im new to the site, so I don't know how to upload photos, but I can try. Theres really nothing to photo though, if you look at your bike, you will know where i'm talkiing about.

The obvious questions are:
Has anyone heard of or had this happen to them?
Is it possible that it is just the gasket and not something more severe?
If it is the gasket/seal, can I just remove the 11 nuts on that cover and pull it off, replace the gasket, refill with engine with oil and pretend like this didn't happen?


Thanks, I'll keep my fingers crossed that this is something simple.

[Easy Rider]

and went one tooth down on the countershaft sprocket though,

Is it possible that it is just the gasket and not something more severe?


Yes, likely I think. First check the nuts to be sure they haven't come loose.

Check the shop manual available for download here...........to be sure that it is a simple cover and not a mounting point for some transmission shafts or similar. It would be a shame to have your transmission fall apart when you remove it.

Then I'd suggest that you take a picture to a dealer and ask them; you can order a gasket while you are there........OR you could try to temporarily plug the hole with rtv and ride it to the dealer. Resist the temptation to make a permanent repair with RTV......because it will never be really permanent.

Your sprocket change is interesting. Are you climbing hills.....or pulling stumps ??? :biggrin:
I think that's not a good idea as you would tend to over-rev the engine.

[IndyKTM]

Lol! I typed that wrong...I went one tooth up on the sprocket!! I was looking for less vibration and easier load on the little engine, 5th takes forever to get up to speed now.
Nuts are tight. I was also worried that the cover was a mounting point for something, if it is, then I wouldnt know how you put the bike together at all. One side HAS to be able to come off I would think. As for taking the bike to the dealer...I was wanting to avoid this for a couple reasons. First being cost. I'm unemployed right now. Second being that I don't trust them...I like to do my own work on my bikes. I have never let myself down. I have always done a good job so there's no reason to stop doing my own work. I was thinking of using some high temp RTV, but it is just a band-aid. I really want to fix the thing. I was hoping someone has had some experience with this. I was kind of wondering why the seal blew there...if there was any significance to that location or if it was just dumb luck that the seal went in that place.
Thanks for the suggestion with the manual!! That should tell me if it is a mounting point for anything!! :2tup:

[IndyKTM]

After looking at the parts manual, it doesn't LOOK like there are any mointing points on the inside of the cover, but the pic is kind of vague. I really need someone out there who knows one way or another to help me out on this one because I just don't know. It sems obvious to me that it is the gasket, but taking that cover off and having a spring shoot off, or some bearing fall out would be catastrophic.
Please help.

[alantf]

Indy, we really need photos. Go to "post reply">"browse">"add the file">"put in line">"submit" The uploader on the site will do it for you. :2tup:

[IndyKTM]

Here they are. I don't know if you can see it but there is something that looks like a crack on the case, but it is not a crack. It is from the molding of the motor, and it IS NOT where the oil is coming from. The oil is coming from the seal just to the left of the line about 1/8 inch away. The line doesn't seem related at all to the oil coming from the seal...at this time. in one picture I started the bike for a second to show where the oil is coming from. Hope this helps!
Thanks for the walkthrough on posting a pic!!

[3-D Video]

... taking that cover off and having a spring shoot off, or some bearing fall out would be catastrophic.

I've had my fair share of blown gaskets, but I'm new to the GeeZer and can't help you there.
However, and I've never done this even though it seems like a very good idea; one I heard from "The Tappet Brothers" (Click and Clack), and one which I wish I had followed many times in the past... Video tape what you're doing. It could help you in finding that spring or bearing, and, you'll see where, if any, mistakes you've made along the way… And, you'll have a useful documentary to share with the rest of us :)

[Easy Rider]

I really need someone out there who knows one way or another to help me out on this one because I just don't know.

I honestly have only one thing to say: Don't be stubborn to the point of being stupid. If you don't find someone "online" who appears to be reliable.......THEN GO TO THE DEALER. Simple advice to go along with ordering a new gasket should be FREE.

Use of RTV should be considered an emergency measure only. It can pop loose anytime.....and your constant attention to it while you are riding might result in an accident. :cry:

[IndyKTM]

Easy there Easy. I know you're respected on here, but my choice to not trust local dealers comes with merit. I'm not being stubborn or stupid...I'm using the previous experiences of my own and of those I trust and respect. Unfortunately, my local dealers lack knowledge of their bikes and will squeeze most people for every penny of labor, and do so without even solving the mechanical problem (sometimes). This is a GZ forum, and it's logical to present the issue to the community on here. It might even be an issue that is frequently occurring on these bikes, I don't know. So it was worth a shot. I know for a fact that my local dealers sell very few if any of these bikes, let alone work on them. So the prospect of driving to one with my bike, or with it in my truck, would be a waste of time. Besides, I could call them first and order the part over the phone.
I know your intentions are good, but you really don't know my neck of the woods. I do appreciate your suggestions and help from anyone is much appreciated. Bikes can be finicky as we all know, it helps to have a community of those who enjoy a certain bike as much as you do who you can come to ask questions. If I lived back west where I grew up I wouldn't hesitate to take it to a dealer, but around here, the dealers are just bad news.

[blaine]

From what I can see from your pictures It looks like the clutch cover gasket leaking.The gasket went on mine with any warning.New gasket is around $25.00 and about a hour work. :itsokay: :tup: Nothing to fly out when you take cover off. :rawk:

[IndyKTM]

blaine, those are the exact words I was looking to hear. I thought this may be a problem that has been known to happen. I looked in the maintenance/rebiuld manual and it didn't mention anything about mounts or bearings or anything else when removing the clutch cover. It just stated..."lossen nuts and remove clutch cover." I figure this would have been the point in the manual where it would state if something impending would happen if you were to just remove it. Your words give me relief. Hearing someone else say they have done this exact thing before is great.

I would like to know if there was anything different about the way you were riding before this leak occurred that may have caused it. Were you riding fast, or do you take it on the highway much? I do take mine on the highway from time to time and was wondering if this may have contributed to this issue.
Thanks blaine!!

[Water Warrior 2]

If my memory is correct there was some one(possibly Blaine) who posted pics of the clutch cover removal and innards of the case. Nothing fell out and the procedure was as Blaine mentioned. Simple R+R. Let's just hope no internal damage was done with such a low oil level and you will be on your way again with a new gasket.

[blaine]

I would like to know if there was anything different about the way you were riding before this leak occurred that may have caused it. Were you riding fast, or do you take it on the highway much? I do take mine on the highway from time to time and was wondering if this may have contributed to this issue.
Thanks blaine!!

It had nothing to do with the way the bike was operated.The gasket is very thick and drys out and gets very hard and brittle.It is very hard to remove the old gasket from the clutch cover.I tried to scrape the old gasket off with no luck,as it is very easy to gouge the aluminum.I used a Dremel tool with a sanding drum on it,removed all the old gasket in about 10 mins.You need to remove the foot peg bracket (2 bolts) for clearance.Good-luck.
:rawk: :2tup:

[IndyKTM]

Great! I have a dremel and a sanding drum. As for damage, I quickly filled the bike with oil when I got home and fired it right back up. It sounds perfect. However, I don't know how long I was riding low on oil. I'll do an oil change and inspect for excessive shavings (or chunks). But the bike gave me no indication that it was upset about it's situation. It has less than 7,000mi and it's an 2004. I want it to hang in there for a while. A little off topic, but what's the value for bike like this in decent condition with $150 saddlebags and a nice windscreen? I bought it for around $1500 about two years ago.

[blaine]

Bikes are worth more hear on the east coast.I sold my 99 about 6 weeks ago for $2200.00, but it had a lot of aftermarket parts and pieces that made it a "one of a kind" as you can tell from my avatar.
:2tup: :roll:

[Easy Rider]

Easy there Easy. I know you're respected on here, but my choice to not trust local dealers comes with merit. I'm not being stubborn or stupid...I'm using the previous experiences of my own and of those I trust and respect.

OK, fine. I have no way to know about your "special circumstances".

My advice applies in general.......and maybe even in your case if you couldn't get an answer any place else.

It looks like you have a good answer now so the point is moot.
Good luck in gettin it fixed; hope it all goes well !! :2tup:

[Easy Rider]

I used a Dremel tool with a sanding drum on it,removed all the old gasket in about 10 mins.

You must have a light touch and a very steady hand.

That operation would make me nervous as hell......and probably result in more than one gouge.

Isn't there some kind of solvent stuff made to soften and remove old gaskets ???

[blaine]

You must have a light touch and a very steady hand.

That operation would make me nervous as hell......and probably result in more than one gouge.

Isn't there some kind of solvent stuff made to soften and remove old gaskets ???


I used a 120 grit sanding drum set at low speed,no chance of gouging.There are lots of solvents for removing gaskets,I choose not to use them as I have no sense of smell.

:2tup:

[chandlerbingfl]

Posted previously: My oil leak post (http://www.gz250bike.com/forum/viewtopic.php?f=7&t=3660)

I had what appears to be the same issue and since I have an extended warranty took the bike to the dealer where purchased and it turns out is was infact the gasket. Mine was leaking from approximately the same spot...

Unfortunately it took them 4 days to actually look at the bike and now it's going to take 5-7 business days to get a replacement gasket...

Gotta love an extended warranty - woot!

Can't wait to get back on though!

Chandlerbingfl

[blaine]

I would be very careful when you get it back that you didn't do any damage to the engine when it was low on oil.Any issues should be addressed before the warranty runs out.
:cool: :)

[chandlerbingfl]

Yes agreed but I would hope that the dealer would be aware of the situation and take time to check for any collateral damage..

chandlerbingfl