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

[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]

Originally Posted by IndyKTM

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]

Originally Posted by 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.

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]

Originally Posted by blaine

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]

Originally Posted by Easy Rider

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

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: