oil pumping out the exaust!

Wondering if anyone else has ever had this problem. 1982 KZ 1100 A2. Complete top end rebuild-new valves, guides, seals, bored cylinders .030 over, new pistons, rings...you get the idea. The rubber boots between the airbox and carbs were shot so I went with pods but left the airbox in place with all hoses still plumbed. After carful reassembly engine fired right up but immediatly started smoking horribly and oil was actually comming out the exaust. First thought was the rings so I disassembled the top end and found every thing was good (no broken rings and in correctly). I've had the top end appart about six times looking for something missing or broke. I'm convinced it is caused by something that was modified from the rebuild. Seems like the crankcase is being over pressurized but the vent is not plugged and oil is not poring out of the elbow. Could it be smog stuff since it is still in place? Perhaps an oil port plugged forcing oil into the cylinders? BTW..I used a new two piece head gasket with center o-ring and new corner stud o-rings when I first assembled it and once since. Also, compression test and leak down test both check out. [img]

Post edited by: Litespd1100, at: 2007/10/24 12:53

I currently have the exact same symptoms on my CSR. I replaced the head gaskets, o-rings, valve seals, etc. But still have terrible smoking and oil into the exhaust. Took the head back off and found the problem. I have oil leaking around the outside of a couple of valve guides.

Rather than just replacing the guides, I am currently looking for a replacement head. The head I have now has a lot of other problems--broken/stripped threads. So I'm just going to replace the whole damn thing and hopefully that will solve the problem.

Oh, and welcome to KZRider.

"oil leaking around the outside of a couple of valve guides"

Do you mean where the valve guides are pressed into the head?

I thought that my valve guides were worn so I had them all replaced along with new seals...still smoke and oil.

Cleaning out all the oil inside my 4-1 exaust is getting old, I'll never have to worry about it rusting out.

Thanks for the welcome, great forum-great information[

'82 KZ1100
'93 DUC 750SS

Litespd1100 wrote:

"oil leaking around the outside of a couple of valve guides"

Do you mean where the valve guides are pressed into the head?

Yes, that is what I mean. You should be able to check the exhaust side with the head on the engine. Just remove the headers and shine a light into the exhaust ports. If the oil is leaking past the guides, you should see it dribbling down the side of the guide. If the leak is on the intake side, you'll probably need to remove the head (or get tricky with a light and mirrors).

Litespd1100 wrote:

Wondering if anyone else has ever had this problem. 1982 KZ 1100 A2. Complete top end rebuild-new valves, guides, seals, bored cylinders .030 over, new pistons, rings...you get the idea. The rubber boots between the airbox and carbs were shot so I went with pods but left the airbox in place with all hoses still plumbed. After carful reassembly engine fired right up but immediatly started smoking horribly and oil was actually comming out the exaust. First thought was the rings so I disassembled the top end and found every thing was good (no broken rings and in correctly). I've had the top end appart about six times looking for something missing or broke. I'm convinced it is caused by something that was modified from the rebuild. Seems like the crankcase is being over pressurized but the vent is not plugged and oil is not poring out of the elbow. Could it be smog stuff since it is still in place? Perhaps an oil port plugged forcing oil into the cylinders? BTW..I used a new two piece head gasket with center o-ring and new corner stud o-rings when I first assembled it and once since. Also, compression test and leak down test both check out. [img]<br><br>Post edited by: Litespd1100, at: 2007/10/24 12:53

First thing I would suspect in your situation is an overlapped oil expander ring or rings. Look at the plugs, they will give an indication which cylinders are involved You would not be the first.

Skyman wrote:

Litespd1100 wrote:

"oil leaking around the outside of a couple of valve guides"

Do you mean where the valve guides are pressed into the head?

Yes, that is what I mean. You should be able to check the exhaust side with the head on the engine. Just remove the headers and shine a light into the exhaust ports. If the oil is leaking past the guides, you should see it dribbling down the side of the guide. If the leak is on the intake side, you'll probably need to remove the head (or get tricky with a light and mirrors).

i can look into the intake runners on my csr with the carbs off and the boots on.

I agree with Modprod. You wouldn't be the first to overlap the oil rings.

Please don't ask me how I know.:pinch:

if u find that it is leaking around your new guides i would think u could repair it yourself. u could mark the bad 1's carfully so they can be replaced in exactly the same orientation . then head the head in an oven (when mommys not home,this is VERY important)at 359* then u can easily drive them out from the bottom.make up a punch that will slide in the guide with a lip to cath the end, or posibly a wood dowel.u should be able to put a sealer on it and replace it maybe some yamabond would be good for this.Any ideas guys.then replace in oven (dont forget the mommy part)replace valve guide .then check for a good valve seal by filling the chamber with thinner to see if it leakes by the valve. lap if neccesary. and away u go .its worth a try, anyways.

Unitrak wrote:

I agree with Modprod. You wouldn't be the first to overlap the oil rings.

Please don't ask me how I know.:pinch:

Yeap, don´t ask me either:angry: :pinch: #1 oil expander ring was faulty......

Thanks all.....I'll check the guides and rings again.

I did have this same problem last summer:
my deal was that I didn't drain the oil out when I did the top end. and after I finished I put 3.7L of new oil in the crank case. so long story short I had double the necessary oil inside the engine.

ps. I disassembled and reassembled 4 times before I realized what was going on.