2011 KLR 650: Oil leak through the weep hole - recently replaced the WP seals

[drbarq]

Hey guys,

Looking for some help or alternative solutions to trying to fix this.

Currently in Santiago riding south with my KLR and dealing with an oil leak issue. I am up against time and part availability.

Back story: My bike started leaking oil out of the weep hole a few weeks back. I figured it was the oil seal behind the water pump and had my family bring me new engine/water pump gaskets, and mechanic and oil seals to be replaced. I took the parts to a shop and had them installed. The shop was reputable and believe they did do the correct job. I saw the old seal and the opening was oblong and there was black markings on the impeller shaft.

Since installation of the new parts the leak has accelerated. This leads me to think either the oil seal was seated incorrectly, was damaged, or the impeller shaft bearings are going causing a vibration and in consequence the leak.

Solutions:
Well DrBarq, crack that thing open and find out. Well I would love to but I can't get the replacement parts in Santiago. I found the mechanic seals but don't have the gaskets, oil seal, impeller shaft, or bearings. Ordering them will take 45 days for them to arrive in Santiago from the dealer. I have my flight out of Buenos Ares on the 16th of December.

The current state of the bike is its leaking a ton of oil, I am fine with adding oil along the way. My concern is if the leak continues to get worse causing the seal to fail completely resulting with the engine unable to hold oil.

My 'you really shouldnt do that' solution is to use gasket sealant to glue a piece of tubing around the weep hole. Allowing me to collect the oil for the time being and if/when the seal fails, I can cap it and stop the oil loss. My logic being, the mechanic seal is new and should hold if/when the void space between the two seals fills with non pressurized oil. I would empty the space after riding.

I understand this is not the right way to fix this but i don't have the time to wait for the parts. Another mechanic suggested removing the bearings and having them repaired. I am under the impression you are not to reuse these bearings once removed as the process to remove them will damage them. Also I feel like this is an even larger gamble as I don't have the seals and provides another opportunity to damage the impeller shaft, which I can't replace.

Below are the OEM part diagrams if anyone happens to have a stash of parts they could sell me in Santiago and bail me out. Are there any other ways I should be looking at this or any other suggestions you could see working?

I just want to get to Ushuaia, I'm not bringing the bike back so this is a one way trip. it just needs to go a short distance of 4000Km. Thank you!

[drbarq]

I ended up opening it and finding the parts. Luckily not the bearings and the seal had been damaged during installation. Replaced the seal and good to go!

[markharf]

I don't want to push traffic away from The Hubb, but when I've had KLR-specific questions like yours I've generally turned to KLR-specific forums. There are quite a few, which you'll find by Googling.

I like the DSN (Dual Sport News, RIP) group run by Fred Hink of Arrowhead Motorsports, but that's probably a function of habit rather than any up to date information. Most of the folks in the KLR forums do not travel the world, so a post from Chile will tend to attract attention.

Hope that's helpful.

Mark

[navalarchitect]

Glad you fixed your problem. It's very easy to catch this seal on installation of the clutch cover, so don't blame your mechanic too much.

For future reference and for others in the same situation, if stuck you don't need an OEM seal - it is a standard 10mm ID, 22mm OD seal and should be available worldwide from most bearing and seal shops in large cities.

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