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]

Originally Posted by IndyKTM

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]

Originally Posted by IndyKTM

... 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]

Originally Posted by IndyKTM

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.

[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: Nothing to fly out when you take cover off. :rawk: