Glass Oil Window on KLR

klrman

New member
Anybody know how full the oil window should be? The manual says to the top, but I have found that when I keep it at the top line, the oil tends to seep out the oil filter O-ring down the cases and a little out the oil filler cap. I'm thinking of 3/4 full but I was just wondering if anyone had the same thing happen when the oil was to the top line?
 
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tashunka

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Mine is to the top, no leaks at all.
 

Yak_KLR650

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It takes 2.5 litres. On mine that puts it above the top of the sight glass. If it drops much below, I add oil, but I've never had to do that between oil changes. I'd check your O ring for nicks or pinches. It shouldn't be leaking from there. Filter cover bolts are torqued properly? While your at it, is the filter tube in place, the right way? If it's in backwards I think the cover can bottom on it and not seat properly. Narrow end towards the engine.
 

klrman

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Yes, the filter pin is narrow side towards the engine and bolts torqued correctly. I am getting a little spooked now as this all happened when I changed the oil filters to the stainless steel ones from dual star. The exact same thing happened to my brothers bike the same time as I put the stainless oil filter in his bike too.
 
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dooveman

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An epiphany:shock:

Reminds me of when I was about to install an after market head gasket in my Corsica years ago. I stared at it and thought, "I wonder if I should use an after market product in an area where fitis important." Then I went to the dealership and bought the stock head gasket for 3x what it's worth.

Then I totalled the car 2 weeks later.It's funny howirony has a way of punishing us when we get too wise.

Brian
 

klrman

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I was staring at the SS oil filter too and wondering if I should put it in. When I opened the package, it said something like "no warranty on this item"? but I put it in anyway as so many race cars and bikes use the SS filters, but I have my doubts now. Will torque the bolts again and change the o-rings. If that doesn't work then I will put in a stock paper filter again and call it a day.
 

masonjarz

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I just changed the oil and filterin my KLR for the second time (I haven't owned it that long) and I put exactly 2.5 litres.

The oil went right over the top of the sight glass and I was a little concerned that perhaps it hadn't fully drained. There were no leaks and everything looked good.

Now that some others are having the same experience, I feel better!
 

BMWNut

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klrman wrote:
Anybody know how full the oil window should be? The manual says to the top, but I have found that when I keep it at the top line, the oil tends to seep out the oil filter O-ring down the cases and a little out the oil filler cap. I'm thinking of 3/4 full but I was just wondering if anyone had the same thing happen when the oil was to the top line?
The head mechanic at the shop told me to "make sure the O-ring was dry when I re-installed it" as a wet O-ring will leave a pre-made path for leakage.
 

Buck

Moderator
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masonjarz wrote:
I just changed the oil and filterin my KLR for the second time (I haven't owned it that long) and I put exactly 2.5 litres.

The oil went right over the top of the sight glass and I was a little concerned that perhaps it hadn't fully drained. There were no leaks and everything looked good.

Now that some others are having the same experience, I feel better!

Did you drain 2.5 litres?... not like anyone would check. :?

I found if my bike drains overnight, a further 1/2 litre drains out.
 

klrman

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Well, I never tried putting in a dry ring. Actually, it always leaked a little even when new, but upon closer inspection, there is an imperfection in the casing that I just ground down and it leaks less now, but still leaks.
 

Buck

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Is this a new bike under warranty? It shouldn't leak at all.
Local dealer was saying that the KLR is now manufactured in Asia, not Japan to lower costs. Has quality remained the same or dropped?
 

Yak_KLR650

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The KLR is assembled in Thailand, from (I believe) Japanese parts. Quality should have remained the same.

And Japan is part of Asia.:ted:
 

klrman

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It is new and under warranty, but I don't think the dealer would consider ordering a new case for me so I just did what I could. It is not the perfect solution but it slowed down the leak.
 

Buck

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Yak_KLR650 wrote:
And Japan is part of Asia.

Oops...pardon my hurried blunder. I'lltry to be more accurate next time. I should have said... "assembled elsewhere in Asia for economic reasons." Hopefully quality has not suffered. Time will tell.
 

klrman

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My wife was assembled in Thailand too! I noticed when I bought a new stock airfilter that it came from Thailand too but the price was very North American...$45.00. but I got even and just won a bid on ebay for 5 KLR filters basically new for $41..haha. The stock tires say "Made in Thailand" too.
 
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