KLR Clutch Side Gasket problem

Discussion in 'Thumpers' started by FDKLR, Jun 21, 2013.

  1. FDKLR

    FDKLR Been here awhile

    Joined:
    Jul 31, 2006
    Oddometer:
    456
    Location:
    Mount Horeb, WI
    I had the Clutch side gasket on my KLR fail.
    I replaced the gasket and within about 2000 miles it began leaking again. This time below and slightly back of the water pump area against the block.

    I took everything apart and block and cover do not have any scratches or gouges. So I replaced the gasket and put everything back together again. I let the bike sit over night and I noticed that a small amount of oil is beginning to leak in that same area again.

    Has anyone else had any issue with this and or has any one just used RTV in place of the gasket to possibly fill any voids or if the cover has a slight warp in it.

    Thank you,
    Brian
    #1
  2. Tsotsie

    Tsotsie Semi-reformed Tsotsi

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    Nov 12, 2007
    Oddometer:
    2,298
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    South Texas
    Never had that problem. Find the cause. Old gasket not propery removed? Put a straight edge along the surfaces to see if there is any thing not flat. All bolts correctly torqued? Any possibility that the leak is from the weep hole at the bottom of the water pump and running back?

    Next time use some Hondabond, Yamahabond or Kawasakibond gray sealant - all the same stuff with different labels. Hondabond is avaialble also at their car dealerships. Apply it thinly as some may come off on the inside and eventually get stuck in the oil pump gauze filter.
    #2
  3. FDKLR

    FDKLR Been here awhile

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    Mount Horeb, WI
    I believe that everything is tourqued correctly and I checked again this morning as well.

    All the old gasket has been removed preped and cleaned. These gaskets are fairly thin compared to larger engines.

    I verifed the water pump drain and the drain that has a passageway below the oil filer and those are not leaking.

    I do not have a machine flat deck but it appears relatively flat with a ruler.

    With that gasket maker would you still use a factory gasket as well?
    #3
  4. CA Stu

    CA Stu Thanks Super Moderator

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    Aug 27, 2004
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    Riverside, CA
    I have a leak in the same area, I nicked it prying off the cover when I replaced the clutch.
    It peed pretty good out of the top of the cover there.
    After replacing the gasket and having it still leak, I hit it with some JB weld and that stopped the leak.

    :D
    #4
  5. Tsotsie

    Tsotsie Semi-reformed Tsotsi

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    2,298
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    South Texas
    Yes. Use the 'bond' only where necessary and sparingly both sides of the gasket.
    #5
  6. FDKLR

    FDKLR Been here awhile

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    Jul 31, 2006
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    Mount Horeb, WI
    Thanks for the replies. I may try the JB weld, or if I get excited I will pull it all apart again and try the gasket with sealer. I would hate to waste all that new oil and coolant though.
    #6
  7. Old Kiwi#99

    Old Kiwi#99 Been here awhile

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    Nov 5, 2006
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    Middle Earth, New Zealand
    absolutely no reason why you cant drain the oil and the coolant into clean (seperate, obviously) containers and reuse.
    #7
  8. Kawidad

    Kawidad Long timer

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    Jul 9, 2005
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    Central Coast, Cal
    I had that problem when using an aftermarket gasket. I replaced it with an OEM gasket and the leak stopped. In fact, I used several aftermarket gaskets (Tusk brand, FWIW) and most of them leaked and had to be replaced by OEM's, which promptly stopped all leakage. :deal
    #8