Maintenance & Technical > KX500 Original

oil leak

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Hillclimb#42:
 You have to be careful with that damage. The clutch barely has clearance there. The hump that is inside the cover will wind up rubbing the pressure plate when engaged. I would also think it would be better to have the back side clean and not have any oil to burn. It has to be a precision repair because the brake pedal rides there and the pressure plate is on the other side. So it has to be filled and smoothed back out to be right. The big problem is that hammering on it to get it back to shape will probably weaken the aluminum right there. I always say " it doesn't hurt to leak a little oil, it only messes stuff up when you run out." Seriously though, a shiny new anodized cover looks pretty killer on your KAW..... 

don46:
Where do you find a "shiny new anodized cover"? Short of building one yourself.

You will have to remove the cover to have it welded, since it's aluminum it will have to be super clean. The crack you have is common to the K5 that has been laid over, Mine doesn't have it, but at least 3 that I have bought have the same problem, I've repaired 2 of them and will do the last one when I get it off. A good welder can fix it as good as new, and a little time on your part, you won't even know it was cracked. 42 is right, you can't have to big a knob on the inside, it will have to be ground down flush, no big deal.

If it is your intention to keep the bike, I would either replace it or get it welded up.

KXcam22:
I took mine off an pounded the dent out for clutch clearance.  Don I had to use Mapp gas to make the alum epoxy work, propane wasnt hot enough.  How's this for ironic,  I was the one yapping about the alum stuff and I just remembered that mine had a tiny crack once and I used a bit of JB weld inside. Oops. Cam.

PS been on there 10 years so I guess it works good!!

BDI:
The cover should be taken off then the dent heated with propane torch. I would clean the cover and crack with brake cleaner first to remove oil. Then I would heat the dent so I could pound it out from behind to make it flat again if you do not heat it you run the risk of nocking out a big piece and making a hole. Heating it will also help to cook the oil out of the crack so it can be welded. Then I would tig weld it or have it tig welded by some one who could. Then I would grind and refinish the weld so you could not tell it ever happened. There is a difference between fixing it properly or scabing it, if all you care about is if oil comes out then you could just smear some rtv on it who knows it might last for six years.

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