Oil leak > Clutch housing

[kx250pwr]

hey first time poster. so the story goes, got my bike a few months ago -1994 kx250. had some problems with running rich so the top end was stripped down and found carby was way out so the float level was fixed up and top end freshened up (piston and rings are still good for the time). Goes like a rocket now

So now i cant understand why there is oil leaking from the clutch housing (not clutch cover, next gasket in) at the bottom, if a fairly steady leak and i had a good look and cant see any cracks in the case at all so it must be the gasket, but it only leaks when the engine is running, what do you think? there was no gear oil in it when i got it so its a big problem, should i just replace that gasket and see what happens

also is it too difficult to replace. i gotta take the kickstarter and waterpump off so anything else?

thanks

[KickassKX125]

No you dont have to take the kick start off to get to it only the break pedal, it's easy to get off, and also yes do replace the gasket, if it still leaks it's fairly serious and what I mean be that is the casings are knackered + need replacing, if it is then it will cost a fair bit to repair - infact its cheaper to buy a new one

[kx250pwr]

yeh thats what im worried about, visually the area of the leak looks good, i cant see how its leaking from the gasket, all the bolts are tight as well.

oh well hopefully its just a gasket or im stuffed! cant affort to spend any more on it at the moment, if it still leaks could i try using that gasket cement on it? i know dodgy but i dont want to fork out any more money than i have already.

riduculous had to spend $40 on a damn head gasket.. still fuming about that!

[KickassKX125]

well you could try the gasket cement - personally i've never tried it because people who get me to repair there KXs want genuine parts which cost the flaming earth, but flipping eck you've been ripped off with the head gasket and a half!!

[kx250pwr]

well i asked him if they made anything aftermarket and he said you could only buy genuine. where can i get them cheaper?

[KickassKX125]

off eBay.
The most you will pay on there is $22.50 the least you will pay will be $5.99

[kx250pwr]

will keep that in mind thanks for your help. ill pick up some new gaskets tomorrow (might have to order them in) and hopefully get them fitted friday night before goin ridin saturday so want to make it reliable. will keep you posted. thanks

[KickassKX125]

no prob if it still doesn't work just post on the forum again ill keep watching out for any new posts =)

[motodemon172]

rocky mountain has cometic gaskets for $8 so their is after market ones.http://www.rockymountainatv.com/vehi...#vehicleSelect to remove the cover all you have to do is gently pry the rear brake pads apart this will allow the rear brake pedal to go down farther then place a screwdriver in the swingarm pivot bolt to hold the lever down.you cover may be warped if you have a flat plate of steel to lay it on to check for warpage.you can try some threebond sealer which is what dealers us use seal the case halves http://www.carlscycle.com/eshopprod_...KET_1104. htm or yamabond http://www.parkeryamaha.com/browsepr...amabond-5.html both you should be able to get at a dealer.you can also try 2 gaskets if the cover is warped.

[kx250pwr]

cheers. picked up the new gasket today, so friday night it should be goin on hopefully. will check for warping, cracks etc when its off... but i think the gasket has been sucked in. if the old one still looks ok will probably use some gasket sealant of some sort on the new one. thanks

[gaz]

On my kx125'02 the brake pedal, kickstart hasto come off, also you need to take the impeller off the waterpump to get the cover off. I don't know if its the same for the 250. However I had a similar problem and it was the gasket leaking. A new gasket and a coating of spray on (Hylomar 150) and it works great. I also use it on the head gasket. When putting the gasket on I layed the bike on its left side so the gasket would sit and stay put while I put the cover on. While the cover was off I check the water pump oil seals and shaft. Other than that its easy to do.

[kx250pwr]

yeh thats what i thought had to come off. thanks for clearin it up. i got a new water pump gasket aswell so thats all good. but definately lookin somewhere esle for spares next time, the dealer charger a fortune and thats just gaskets! thanks

[iracekx]

Originally Posted by gaz

On my kx125'02 the brake pedal, kickstart hasto come off, also you need to take the impeller off the waterpump to get the cover off. I don't know if its the same for the 250. However I had a similar problem and it was the gasket leaking. A new gasket and a coating of spray on (Hylomar 150) and it works great. I also use it on the head gasket. When putting the gasket on I layed the bike on its left side so the gasket would sit and stay put while I put the cover on. While the cover was off I check the water pump oil seals and shaft. Other than that its easy to do.

The water pump impeller has to come off on a 250 to replace that gasket I had to replace the kick starter rod that goes on my 250 it sheared off a few years back flush with the casing so I had to replace gasket when I replaced part. I was going to ride kick on the third time it broke off. My next projest that I have to do is replace the seal that goes where the shifter attaches if I remember correctly I did this on my buddy's YZ250 and it was a pain getting the old one out. I guess I will get the pick set out and start digging it out. I remember the new one went in really easy of course this was on a Yamaha.

[kx250pwr]

Well, was able to replace the gasket the other night, the old one still looked ok but it doesnt seem to leak anymore so happy about that. its definately had work done in the clutch area before. went real good all day yesterday, exept accidently ran the tank dry, then remebered my bike doesnt have a reserve had to push 1 kilometre up a slight incline before some nice people lent me some fuel. cheers

[YurFatMom]

Great to hear your leak is gone!

Originally Posted by kx250pwr

accidently ran the tank dry, then remebered my bike doesnt have a reserve had to push 1 kilometre up a slight incline before some nice people lent me some fuel. cheers

I ran my 125 out a few times, but once it was pretty bad. I went down 2 large hills, and into the swamp and got a little ways into a pond, and ran out of fuel. Then I had to pull it out of the goo, and push it up the 2 big hills to get it over to a neighbors house. That was a workout. He didnt have any mixed gas, but he gave me a ride home so I could get my truck and get my bike. I love nice people like that!

[kx250pwr]

yeah i suppose its not really wise thing riding by yourself, but no-one could keep up!! specially when it was sittin on 1/3 tank of 103 octane race fuel just glad to have it runnin properly since i got it, didnt really have it past 85% throttle all day , just churns the back tyre in all gears.. and thats with a tired top end, runnin 30:1 and a standard plug.