t-mod - how?

[dbs52a]

Your album is on the site but no pictures in it. Why don't you take off the filter cap and take some close up photos of the two mating surfaces and post them. Also a side view shot of the cap to see if there may be slight warpage.

--- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > Just wanted to post some pictures (three in Photo Section) of my > continuing problem. Due to crummy weather and up to my kester doing > income taxes, I haven't gotten to the dealer yet to see what they can > do. > > The pic of the side case does and doesn't look that bad. This was > taken after 40 miles of freshly graveled roads in a 150 mile day. > The oil didn't run all of the way down and drip off the bottom > because of the thick coating of stone dust. But it shows the blow > back pattern of oil from the bottom of the filter cap. > > Don > R100, A6F KLR > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > Just asking. After my first ride, I notice that a small amount of > oil > > escaped from the lower half (bolt to bolt) of the cap. I took the > cap > > off and in retrospect the o-ring (in a groove on the cap's skirt) > > probably wasn't being effective because it was so easy to take off > and > > put back on. I talked to the dealer at a later visit (pick up > these > > somewhat deficient and over-priced Kawie manuals) and they gave me > a > > new o-ring to install (I assumed that it would replace the > exisiting o- > > ring in the groove on the cap's skirt). The new o-ring made it a > bit > > harder to overcome its resistance to properly seat the cap. > And "Yes" > > the arrow is up. > > > > I thought that the "beefer" OEM o-ring was going to do the trick > > but... I still have enough oil leaking out after relatively short > runs > > that I need to place cardboard under the bike so as not to stain > the > > garage floor. Heck of a thing for a brand new bike. BTW - I hit > the > > 500 mile mark and loosened and then tightened the Idler lever bolt > to > > 6/7 ft-lbs. I also changed the oil (Kawie 10-40W) and a new Parts > > Unlimited filter. Can't believe that there are any abnormal > pressure > > situations causing the problem. The oil filter by-pass tube is > > properly installed and seated. > > > > My questions are: > > 1.) The Kawie manual isn't as explicit as I would like but > it "almost" > > seems to indicate that an o-ring fits under the lip of the filter > cap > > and if that is the case, I would definitely believe that a good > seal > > would be created. Should I have and o-ring up and under the cap's > > lip? > > 1.) Has this happened to others? > > 2.) If it has, what was your fix? > > 3.) Should I try to cut a gasket out of thin material or use a > silicone > > sealer (must be a hair-line opening), so as not to create any > > unreasonable gaps at either end of the filter . > > > > Don > > R100 Airhead # 6696 > > KLR A6F > > >

[Doug Herr]

On Fri, 7 Apr 2006, dbs52a wrote:

> Your album is on the site but no pictures in it. Why don't you take > off the filter cap and take some close up photos of the two mating > surfaces and post them. Also a side view shot of the cap to see if > there may be slight warpage.

One empty album called: '06 A6F Leaky Filter Cap One with 3 pics called: Leaky Oil Fiter Cap For me, the good one showed up on the second page of albums. -- Doug Herr doug@...

[Don]

Doug is right. The album with a pic of the cap and the filter cavity are behind the side case picture on page # 2 of the photo section. I guess I mis-fired on empty album. Don R100, A6F KLR

--- In DSN_KLR650@yahoogroups.com, "dbs52a" wrote: > > > Your album is on the site but no pictures in it. Why don't you take > off the filter cap and take some close up photos of the two mating > surfaces and post them. Also a side view shot of the cap to see if > there may be slight warpage. > > > > > > > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > Just wanted to post some pictures (three in Photo Section) of my > > continuing problem. Due to crummy weather and up to my kester > doing > > income taxes, I haven't gotten to the dealer yet to see what they > can > > do. > > > > The pic of the side case does and doesn't look that bad. This was > > taken after 40 miles of freshly graveled roads in a 150 mile day. > > The oil didn't run all of the way down and drip off the bottom > > because of the thick coating of stone dust. But it shows the blow > > back pattern of oil from the bottom of the filter cap. > > > > Don > > R100, A6F KLR > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > > > Just asking. After my first ride, I notice that a small amount > of > > oil > > > escaped from the lower half (bolt to bolt) of the cap. I took > the > > cap > > > off and in retrospect the o-ring (in a groove on the cap's skirt) > > > probably wasn't being effective because it was so easy to take > off > > and > > > put back on. I talked to the dealer at a later visit (pick up > > these > > > somewhat deficient and over-priced Kawie manuals) and they gave > me > > a > > > new o-ring to install (I assumed that it would replace the > > exisiting o- > > > ring in the groove on the cap's skirt). The new o-ring made it > a > > bit > > > harder to overcome its resistance to properly seat the cap. > > And "Yes" > > > the arrow is up. > > > > > > I thought that the "beefer" OEM o-ring was going to do the trick > > > but... I still have enough oil leaking out after relatively > short > > runs > > > that I need to place cardboard under the bike so as not to stain > > the > > > garage floor. Heck of a thing for a brand new bike. BTW - I > hit > > the > > > 500 mile mark and loosened and then tightened the Idler lever > bolt > > to > > > 6/7 ft-lbs. I also changed the oil (Kawie 10-40W) and a new > Parts > > > Unlimited filter. Can't believe that there are any abnormal > > pressure > > > situations causing the problem. The oil filter by-pass tube is > > > properly installed and seated. > > > > > > My questions are: > > > 1.) The Kawie manual isn't as explicit as I would like but > > it "almost" > > > seems to indicate that an o-ring fits under the lip of the > filter > > cap > > > and if that is the case, I would definitely believe that a good > > seal > > > would be created. Should I have and o-ring up and under the > cap's > > > lip? > > > 1.) Has this happened to others? > > > 2.) If it has, what was your fix? > > > 3.) Should I try to cut a gasket out of thin material or use a > > silicone > > > sealer (must be a hair-line opening), so as not to create any > > > unreasonable gaps at either end of the filter . > > > > > > Don > > > R100 Airhead # 6696 > > > KLR A6F > > > > > >

[dbs52a]

Don: From looking at the first two photos, it almost seems that the leak begins at the left side bolt hole and thereafter seeps downward toward the bottom and slightly upward again on the right side. The second photo also seems to indicate a visual anomoly in the immediate vicinity of the left side of the left bolt hole. This could be a casting or machining flaw. If it is, I'd report it to the dealer for repair. To confirm that the leak is at the left bolt hole, re-assemble the oil cap, clean the area very well and dust it with talcum powder or similar fine powder like corn starch or even flour. fire up the engine and watch for the leak. It may happen with cold oil account this is when the pressure will be at it's highest or it may happen later as the oil warms and becomes more fluid. Do the test and let us know. Don

--- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > Doug is right. The album with a pic of the cap and the filter cavity > are behind the side case picture on page # 2 of the photo section. I > guess I mis-fired on empty album. > > Don > R100, A6F KLR > > --- In DSN_KLR650@yahoogroups.com, "dbs52a" wrote: > > > > > > Your album is on the site but no pictures in it. Why don't you > take > > off the filter cap and take some close up photos of the two mating > > surfaces and post them. Also a side view shot of the cap to see if > > there may be slight warpage. > > > > > > > > > > > > > > > > > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > > > Just wanted to post some pictures (three in Photo Section) of my > > > continuing problem. Due to crummy weather and up to my kester > > doing > > > income taxes, I haven't gotten to the dealer yet to see what they > > can > > > do. > > > > > > The pic of the side case does and doesn't look that bad. This > was > > > taken after 40 miles of freshly graveled roads in a 150 mile > day. > > > The oil didn't run all of the way down and drip off the bottom > > > because of the thick coating of stone dust. But it shows the > blow > > > back pattern of oil from the bottom of the filter cap. > > > > > > Don > > > R100, A6F KLR > > > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > > > > > Just asking. After my first ride, I notice that a small amount > > of > > > oil > > > > escaped from the lower half (bolt to bolt) of the cap. I took > > the > > > cap > > > > off and in retrospect the o-ring (in a groove on the cap's > skirt) > > > > probably wasn't being effective because it was so easy to take > > off > > > and > > > > put back on. I talked to the dealer at a later visit (pick up > > > these > > > > somewhat deficient and over-priced Kawie manuals) and they gave > > me > > > a > > > > new o-ring to install (I assumed that it would replace the > > > exisiting o- > > > > ring in the groove on the cap's skirt). The new o-ring made it > > a > > > bit > > > > harder to overcome its resistance to properly seat the cap. > > > And "Yes" > > > > the arrow is up. > > > > > > > > I thought that the "beefer" OEM o-ring was going to do the > trick > > > > but... I still have enough oil leaking out after relatively > > short > > > runs > > > > that I need to place cardboard under the bike so as not to > stain > > > the > > > > garage floor. Heck of a thing for a brand new bike. BTW - I > > hit > > > the > > > > 500 mile mark and loosened and then tightened the Idler lever > > bolt > > > to > > > > 6/7 ft-lbs. I also changed the oil (Kawie 10-40W) and a new > > Parts > > > > Unlimited filter. Can't believe that there are any abnormal > > > pressure > > > > situations causing the problem. The oil filter by-pass tube is > > > > properly installed and seated. > > > > > > > > My questions are: > > > > 1.) The Kawie manual isn't as explicit as I would like but > > > it "almost" > > > > seems to indicate that an o-ring fits under the lip of the > > filter > > > cap > > > > and if that is the case, I would definitely believe that a good > > > seal > > > > would be created. Should I have and o-ring up and under the > > cap's > > > > lip? > > > > 1.) Has this happened to others? > > > > 2.) If it has, what was your fix? > > > > 3.) Should I try to cut a gasket out of thin material or use a > > > silicone > > > > sealer (must be a hair-line opening), so as not to create any > > > > unreasonable gaps at either end of the filter . > > > > > > > > Don > > > > R100 Airhead # 6696 > > > > KLR A6F > > > > > > > > > >

[Don]

Don: When I took the picture, I too noticed that step right by the left bolt hole. When the bolts are tightened up, the cap seems to be flush all the way around the top of the cavity lip (not being mis- aligned by that step). I also discounted the step since it is "downstream" of the sealing O-ring. Once the weather clears up a bit more I'll run the test as suggested: dust it with talcum (have that in the garage so I can get max. use of my nitrile grooves) and go for a ride, stop to check, ride, etc. I'll post what the dealer's suggestion is. If it requires a new side case, (being a motorhead I almost hate to say it but...) I may have him pull the other side too and replace the idler lever / spring with one that I'll supply. It might be a good time to clean the oil screen too. BTW - I've seen that there are several replacement spring lengths available. How does one know which one is the best fit so as to order the right one ahead of time? Don R100, A6F KLR

--- In DSN_KLR650@yahoogroups.com, "dbs52a" wrote: > > > Don: > > From looking at the first two photos, it almost seems that the leak > begins at the left side bolt hole and thereafter seeps downward > toward the bottom and slightly upward again on the right side. The > second photo also seems to indicate a visual anomoly in the > immediate vicinity of the left side of the left bolt hole. This > could be a casting or machining flaw. If it is, I'd report it to > the dealer for repair. To confirm that the leak is at the left bolt > hole, re-assemble the oil cap, clean the area very well and dust it > with talcum powder or similar fine powder like corn starch or even > flour. fire up the engine and watch for the leak. It may happen > with cold oil account this is when the pressure will be at it's > highest or it may happen later as the oil warms and becomes more > fluid. Do the test and let us know. > > Don > > > > > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > Doug is right. The album with a pic of the cap and the filter > cavity > > are behind the side case picture on page # 2 of the photo > section. I > > guess I mis-fired on empty album. > > > > Don > > R100, A6F KLR > > > > --- In DSN_KLR650@yahoogroups.com, "dbs52a" wrote: > > > > > > > > > Your album is on the site but no pictures in it. Why don't you > > take > > > off the filter cap and take some close up photos of the two > mating > > > surfaces and post them. Also a side view shot of the cap to see > if > > > there may be slight warpage. > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > > > > > Just wanted to post some pictures (three in Photo Section) of > my > > > > continuing problem. Due to crummy weather and up to my kester > > > doing > > > > income taxes, I haven't gotten to the dealer yet to see what > they > > > can > > > > do. > > > > > > > > The pic of the side case does and doesn't look that bad. This > > was > > > > taken after 40 miles of freshly graveled roads in a 150 mile > > day. > > > > The oil didn't run all of the way down and drip off the bottom > > > > because of the thick coating of stone dust. But it shows the > > blow > > > > back pattern of oil from the bottom of the filter cap. > > > > > > > > Don > > > > R100, A6F KLR > > > > > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > > > > > > > Just asking. After my first ride, I notice that a small > amount > > > of > > > > oil > > > > > escaped from the lower half (bolt to bolt) of the cap. I > took > > > the > > > > cap > > > > > off and in retrospect the o-ring (in a groove on the cap's > > skirt) > > > > > probably wasn't being effective because it was so easy to > take > > > off > > > > and > > > > > put back on. I talked to the dealer at a later visit (pick > up > > > > these > > > > > somewhat deficient and over-priced Kawie manuals) and they > gave > > > me > > > > a > > > > > new o-ring to install (I assumed that it would replace the > > > > exisiting o- > > > > > ring in the groove on the cap's skirt). The new o-ring made > it > > > a > > > > bit > > > > > harder to overcome its resistance to properly seat the cap. > > > > And "Yes" > > > > > the arrow is up. > > > > > > > > > > I thought that the "beefer" OEM o-ring was going to do the > > trick > > > > > but... I still have enough oil leaking out after relatively > > > short > > > > runs > > > > > that I need to place cardboard under the bike so as not to > > stain > > > > the > > > > > garage floor. Heck of a thing for a brand new bike. BTW - > I > > > hit > > > > the > > > > > 500 mile mark and loosened and then tightened the Idler > lever > > > bolt > > > > to > > > > > 6/7 ft-lbs. I also changed the oil (Kawie 10-40W) and a new > > > Parts > > > > > Unlimited filter. Can't believe that there are any abnormal > > > > pressure > > > > > situations causing the problem. The oil filter by-pass tube > is > > > > > properly installed and seated. > > > > > > > > > > My questions are: > > > > > 1.) The Kawie manual isn't as explicit as I would like but > > > > it "almost" > > > > > seems to indicate that an o-ring fits under the lip of the > > > filter > > > > cap > > > > > and if that is the case, I would definitely believe that a > good > > > > seal > > > > > would be created. Should I have and o-ring up and under the > > > cap's > > > > > lip? > > > > > 1.) Has this happened to others? > > > > > 2.) If it has, what was your fix? > > > > > 3.) Should I try to cut a gasket out of thin material or use > a > > > > silicone > > > > > sealer (must be a hair-line opening), so as not to create > any > > > > > unreasonable gaps at either end of the filter . > > > > > > > > > > Don > > > > > R100 Airhead # 6696 > > > > > KLR A6F > > > > > > > > > > > > > > >

[Don]

I was wondering if there are any other "oil fitler changers" out there that remember if their side case has the same step in the metal around the clutch-side bolt hole as depicted in my photos (photo section)? I wanted to be armed with that info prior to going to dealer to rememdy my problem (problem with the bike, my other problems, well ...). Don R100, A6F KLR

--- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > Just wanted to post some pictures (three in Photo Section) of my > continuing problem. Due to crummy weather and up to my kester doing > income taxes, I haven't gotten to the dealer yet to see what they can > do. > > The pic of the side case does and doesn't look that bad. This was > taken after 40 miles of freshly graveled roads in a 150 mile day. > The oil didn't run all of the way down and drip off the bottom > because of the thick coating of stone dust. But it shows the blow > back pattern of oil from the bottom of the filter cap. > > Don > R100, A6F KLR > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > Just asking. After my first ride, I notice that a small amount of > oil > > escaped from the lower half (bolt to bolt) of the cap. I took the > cap > > off and in retrospect the o-ring (in a groove on the cap's skirt) > > probably wasn't being effective because it was so easy to take off > and > > put back on. I talked to the dealer at a later visit (pick up > these > > somewhat deficient and over-priced Kawie manuals) and they gave me > a > > new o-ring to install (I assumed that it would replace the > exisiting o- > > ring in the groove on the cap's skirt). The new o-ring made it a > bit > > harder to overcome its resistance to properly seat the cap. > And "Yes" > > the arrow is up. > > > > I thought that the "beefer" OEM o-ring was going to do the trick > > but... I still have enough oil leaking out after relatively short > runs > > that I need to place cardboard under the bike so as not to stain > the > > garage floor. Heck of a thing for a brand new bike. BTW - I hit > the > > 500 mile mark and loosened and then tightened the Idler lever bolt > to > > 6/7 ft-lbs. I also changed the oil (Kawie 10-40W) and a new Parts > > Unlimited filter. Can't believe that there are any abnormal > pressure > > situations causing the problem. The oil filter by-pass tube is > > properly installed and seated. > > > > My questions are: > > 1.) The Kawie manual isn't as explicit as I would like but > it "almost" > > seems to indicate that an o-ring fits under the lip of the filter > cap > > and if that is the case, I would definitely believe that a good > seal > > would be created. Should I have and o-ring up and under the cap's > > lip? > > 1.) Has this happened to others? > > 2.) If it has, what was your fix? > > 3.) Should I try to cut a gasket out of thin material or use a > silicone > > sealer (must be a hair-line opening), so as not to create any > > unreasonable gaps at either end of the filter . > > > > Don > > R100 Airhead # 6696 > > KLR A6F > > >

[dooden]

Maybe this has been asked, if so, sorry Have you just tried a new O-ring ? Ride it to the local auto parts store, when you get there, remove the oil cap, cover the hole and walk in and ask for a O-ring just like this (point to it) and add but you want the new one to not leak. Humor the counter person who most likely has to put up with alot of buttmunchers all day long) Your wallet might be a buck lighter afterwards. Without actually touching the bike and looking closer, it just looks like a leaky O-ring to me. Maybe they pinched it when adding oil at the dealer, and did'nt bother replacing it, maybe it looked ok ? Who knows. Remember anybody servicing your vehicle will never give it the attention that you will doing it yourself, unless you hamfist everything. Nature of the business I suppose, roll um out to make a profit so the doors can stay open. Dooden A15 Green Ape (currently sun bathing waiting to go riding)

--- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > I was wondering if there are any other "oil fitler changers" out > there that remember if their side case has the same step in the metal > around the clutch-side bolt hole as depicted in my photos (photo > section)? > > I wanted to be armed with that info prior to going to dealer to > rememdy my problem (problem with the bike, my other problems, > well ...). > > Don > R100, A6F KLR

[dbs52a]

BRING IT BACK TO THE DEALER! It's under warranty right?

--- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > Don: > When I took the picture, I too noticed that step right by the left > bolt hole. When the bolts are tightened up, the cap seems to be > flush all the way around the top of the cavity lip (not being mis- > aligned by that step). I also discounted the step since it > is "downstream" of the sealing O-ring. > > Once the weather clears up a bit more I'll run the test as suggested: > dust it with talcum (have that in the garage so I can get max. use of > my nitrile grooves) and go for a ride, stop to check, ride, etc. > I'll post what the dealer's suggestion is. > > If it requires a new side case, (being a motorhead I almost hate to > say it but...) I may have him pull the other side too and replace the > idler lever / spring with one that I'll supply. It might be a good > time to clean the oil screen too. > > BTW - I've seen that there are several replacement spring lengths > available. How does one know which one is the best fit so as to > order the right one ahead of time? > > Don > R100, A6F KLR > > > --- In DSN_KLR650@yahoogroups.com, "dbs52a" wrote: > > > > > > Don: > > > > From looking at the first two photos, it almost seems that the leak > > begins at the left side bolt hole and thereafter seeps downward > > toward the bottom and slightly upward again on the right side. The > > second photo also seems to indicate a visual anomoly in the > > immediate vicinity of the left side of the left bolt hole. This > > could be a casting or machining flaw. If it is, I'd report it to > > the dealer for repair. To confirm that the leak is at the left > bolt > > hole, re-assemble the oil cap, clean the area very well and dust it > > with talcum powder or similar fine powder like corn starch or even > > flour. fire up the engine and watch for the leak. It may happen > > with cold oil account this is when the pressure will be at it's > > highest or it may happen later as the oil warms and becomes more > > fluid. Do the test and let us know. > > > > Don > > > > > > > > > > > > > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > > > Doug is right. The album with a pic of the cap and the filter > > cavity > > > are behind the side case picture on page # 2 of the photo > > section. I > > > guess I mis-fired on empty album. > > > > > > Don > > > R100, A6F KLR > > > > > > --- In DSN_KLR650@yahoogroups.com, "dbs52a" wrote: > > > > > > > > > > > > Your album is on the site but no pictures in it. Why don't you > > > take > > > > off the filter cap and take some close up photos of the two > > mating > > > > surfaces and post them. Also a side view shot of the cap to > see > > if > > > > there may be slight warpage. > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > > > > > > > Just wanted to post some pictures (three in Photo Section) of > > my > > > > > continuing problem. Due to crummy weather and up to my > kester > > > > doing > > > > > income taxes, I haven't gotten to the dealer yet to see what > > they > > > > can > > > > > do. > > > > > > > > > > The pic of the side case does and doesn't look that bad. > This > > > was > > > > > taken after 40 miles of freshly graveled roads in a 150 mile > > > day. > > > > > The oil didn't run all of the way down and drip off the > bottom > > > > > because of the thick coating of stone dust. But it shows the > > > blow > > > > > back pattern of oil from the bottom of the filter cap. > > > > > > > > > > Don > > > > > R100, A6F KLR > > > > > > > > > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > > > > > > > > > Just asking. After my first ride, I notice that a small > > amount > > > > of > > > > > oil > > > > > > escaped from the lower half (bolt to bolt) of the cap. I > > took > > > > the > > > > > cap > > > > > > off and in retrospect the o-ring (in a groove on the cap's > > > skirt) > > > > > > probably wasn't being effective because it was so easy to > > take > > > > off > > > > > and > > > > > > put back on. I talked to the dealer at a later visit (pick > > up > > > > > these > > > > > > somewhat deficient and over-priced Kawie manuals) and they > > gave > > > > me > > > > > a > > > > > > new o-ring to install (I assumed that it would replace the > > > > > exisiting o- > > > > > > ring in the groove on the cap's skirt). The new o-ring > made > > it > > > > a > > > > > bit > > > > > > harder to overcome its resistance to properly seat the > cap. > > > > > And "Yes" > > > > > > the arrow is up. > > > > > > > > > > > > I thought that the "beefer" OEM o-ring was going to do the > > > trick > > > > > > but... I still have enough oil leaking out after > relatively > > > > short > > > > > runs > > > > > > that I need to place cardboard under the bike so as not to > > > stain > > > > > the > > > > > > garage floor. Heck of a thing for a brand new bike. BTW - > > I > > > > hit > > > > > the > > > > > > 500 mile mark and loosened and then tightened the Idler > > lever > > > > bolt > > > > > to > > > > > > 6/7 ft-lbs. I also changed the oil (Kawie 10-40W) and a > new > > > > Parts > > > > > > Unlimited filter. Can't believe that there are any > abnormal > > > > > pressure > > > > > > situations causing the problem. The oil filter by-pass > tube > > is > > > > > > properly installed and seated. > > > > > > > > > > > > My questions are: > > > > > > 1.) The Kawie manual isn't as explicit as I would like but > > > > > it "almost" > > > > > > seems to indicate that an o-ring fits under the lip of the > > > > filter > > > > > cap > > > > > > and if that is the case, I would definitely believe that a > > good > > > > > seal > > > > > > would be created. Should I have and o-ring up and under > the > > > > cap's > > > > > > lip? > > > > > > 1.) Has this happened to others? > > > > > > 2.) If it has, what was your fix? > > > > > > 3.) Should I try to cut a gasket out of thin material or > use > > a > > > > > silicone > > > > > > sealer (must be a hair-line opening), so as not to create > > any > > > > > > unreasonable gaps at either end of the filter . > > > > > > > > > > > > Don > > > > > > R100 Airhead # 6696 > > > > > > KLR A6F > > > > > > > > > > > > > > > > > > > > >

[Ron and Brenda Moorhouse]

Mine looks exactly like yours; the side case, that is! I would go with the last suggestion that you have a bad o-ring. Don wrote: I was wondering if there are any other "oil fitler changers" out there that remember if their side case has the same step in the metal around the clutch-side bolt hole as depicted in my photos (photo section)? I wanted to be armed with that info prior to going to dealer to rememdy my problem (problem with the bike, my other problems, well ...). Don R100, A6F KLR

--- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > Just wanted to post some pictures (three in Photo Section) of my > continuing problem. Due to crummy weather and up to my kester doing > income taxes, I haven't gotten to the dealer yet to see what they can > do. > > The pic of the side case does and doesn't look that bad. This was > taken after 40 miles of freshly graveled roads in a 150 mile day. > The oil didn't run all of the way down and drip off the bottom > because of the thick coating of stone dust. But it shows the blow > back pattern of oil from the bottom of the filter cap. > > Don > R100, A6F KLR > > --- In DSN_KLR650@yahoogroups.com, "Don" wrote: > > > > Just asking. After my first ride, I notice that a small amount of > oil > > escaped from the lower half (bolt to bolt) of the cap. I took the > cap > > off and in retrospect the o-ring (in a groove on the cap's skirt) > > probably wasn't being effective because it was so easy to take off > and > > put back on. I talked to the dealer at a later visit (pick up > these > > somewhat deficient and over-priced Kawie manuals) and they gave me > a > > new o-ring to install (I assumed that it would replace the > exisiting o- > > ring in the groove on the cap's skirt). The new o-ring made it a > bit > > harder to overcome its resistance to properly seat the cap. > And "Yes" > > the arrow is up. > > > > I thought that the "beefer" OEM o-ring was going to do the trick > > but... I still have enough oil leaking out after relatively short > runs > > that I need to place cardboard under the bike so as not to stain > the > > garage floor. Heck of a thing for a brand new bike. BTW - I hit > the > > 500 mile mark and loosened and then tightened the Idler lever bolt > to > > 6/7 ft-lbs. I also changed the oil (Kawie 10-40W) and a new Parts > > Unlimited filter. Can't believe that there are any abnormal > pressure > > situations causing the problem. The oil filter by-pass tube is > > properly installed and seated. > > > > My questions are: > > 1.) The Kawie manual isn't as explicit as I would like but > it "almost" > > seems to indicate that an o-ring fits under the lip of the filter > cap > > and if that is the case, I would definitely believe that a good > seal > > would be created. Should I have and o-ring up and under the cap's > > lip? > > 1.) Has this happened to others? > > 2.) If it has, what was your fix? > > 3.) Should I try to cut a gasket out of thin material or use a > silicone > > sealer (must be a hair-line opening), so as not to create any > > unreasonable gaps at either end of the filter . > > > > Don > > R100 Airhead # 6696 > > KLR A6F > > > Archive Quicksearch at: http://www.angelfire.com/ut/moab/klr650_data_search.html List sponsored by Dual Sport News at: www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Member Map at: http://www.frappr.com/dsnklr650 Yahoo! Groups Links Ron and Brenda Moorhouse Modesto, CA 95356 [Non-text portions of this message have been removed]

[Doug Herr]

On Sun, 9 Apr 2006, Dooden wrote:

> Maybe this has been asked, if so, sorry > > Have you just tried a new O-ring ?

Yup, that is how it started (4/2). He got a new one from the dealer, but it did not fix the problem. He did note something about it being harder to install the cover with the new ring, so maybe the new one did not get enough lube and got damaged on the initial install. Just a thought. -- Doug Herr doug@...