Tach cable oil leak

I recently acquired a leak from my tach cable where it goes into the motor. How do I fix this?

Don't feel alone, KZ's are prone to this problem. Just go to Z1 Enterprises and look up your bike and they have a kit which will fix your problem.

Bluemeanie wrote:

Don't feel alone, KZ's are prone to this problem. Just go to Z1 Enterprises and look up your bike and they have a kit which will fix your problem.

Really? What's in the kit? Mine leaks too and the cable is relatively new.

Can you post a number? I looked at Z1 and can't find anything.

I didn't see the kit either, but there are 2 potential leaks. One is the oring that seals the assm to the head, part # 92055-1149, the other is the inner seal, part # 92050-075. 2 of my KZs leak here too. The MKII assm is stuck to the head and will *not* budge, so a homemade paper gasket sealing the cable to the drive fixed it.

I replaced the o ring and seal on mine the other day and it's really easy. you may want to order a new tach drive gear, mine was worn where the seal rides on the shaft and didn't help the leak any.

The tach guide seal is often the culprit. This one from Z1E may fit, but would check the model application. And if in doubt as to fitment, would call Z1E to confirm before ordering.
Click here > Tach Guide SEAL

These small seals fit inside the housing and around the gear shaft which spins inside the seal. The seal gets hard as a little chunk of carbon over the years from exposure to the heat and oil. May have to pick it out piece by tiny piece. It has a teeny-weeny circular spring inside the seal holding the seal snugly around the spinning gear shaft. If the cable attachment is screwed on tight enough with a good seal between it and the guide housing, any oil leaking past the seal (around the spinning shaft) will go on up inside the tach cable without leaking at the threaded area where the cable from the tach attaches to the guide.

Am uncertain whether or not the 10mm o-ring is available as a separate item from Z1E. Might find it at a local hardware or auto-parts store.

The o-ring fits over the guide when pushed into its recess, and prevents engine oil from escaping around the housing.

Good Luck!

Installing the new seals didn't fix my leak. So I bought a whole new tach gear guide for about 38 dollars from Z1E. That fixed the problem. I should have done that a long time ago. The part number I got is PM81-2230.

According to Kawasaki.com, the tach guide oil seal part# 92050-075 is common to the following models (note same as oem part# shown in Z1E's listing for the Z1) :

EN450-A1 (454 LTD) (1985)
EN450-A2 (454 LTD) (1986)
EN450-A3 (454 LTD) (1987)
EN450-A4 (454 LTD) (1988)
EN450-A5 (454 LTD) (1989)
EX305-B1 (GPz 305) (1983)
KAF450-B1 (Mule 1000)
KAF540-C1 (Mule 2010)
KAF540-D1 (Mule 2020)
KAF540-E1 (Mule 2030)
KAF620-A1 (Mule 2510 4X4)
KAF620-A2 (Mule 2510 4X4)
KAF620-A3 (Mule 2510 4X4)
KAF620-A4 (Mule 2510 4X4)
KAF620-A5 (Mule 2510 4X4)
KAF620-A6 (Mule 2510 4X4)
KAF620-B1 (Mule 2520 Turf)
KAF620-B2 (Mule 2520 Turf)
KAF620-B3 (Mule 2520 Turf)
KAF620-B4 (Mule 2520 Turf)
KAF620-B5 (Mule 2520 Turf)
KAF620-B6 (Mule 2520 Turf)
KAF620-C1 (Mule 2500)
KAF620-C2 (Mule 2500)
KAF620-C3 (Mule 2500)
KAF620-C4 (Mule 2500)
KAF620-C5 (Mule 2500)
KAF620-C6 (Mule 2500)
KAF620-E1 (Mule 3010 4X4)
KAF620-E2 (Mule 3010 4X4)
KAF620-E3 (Mule 3010 4X4)
KAF620-E4 (Mule 3010 4X4)
KAF620-E5 (Mule 3010 4X4)
KAF620E6F (Mule 3010 4X4)
KAF620E7F (Mule 3010 4X4)
KAF620E8F (Mule 3010 4X4)
KAF620-F1 (Mule 3020 Turf)
KAF620-F2 (Mule 3020 Turf)
KAF620-F3 (Mule 3020 Turf)
KAF620-G1 (Mule 3000)
KAF620-G2 (Mule 3000)
KAF620-G3 (Mule 3000)
KAF620-G4 (Mule 3000)
KAF620-G5 (Mule 3000)
KAF620G6F (Mule 3000)
KAF620G7F (Mule 3000)
KAF620G8F (Mule 3000)
KAF620-H1 (Mule 3010 4x4 Advantage Classic)
KAF620-H2 (Mule 3010 4x4 Hardwoods Green HD)
KAF620-H3 (Mule 3010 4x4 Hardwoods Green HD)
KAF620H6F (Mule 3010 4x4 Hardwoods Green HD)
KAF620H7F (Mule 3010 4x4 Hardwoods Green HD)
KAF620H8F (Mule 3010 4x4 Hardwoods Green HD)
KAF620J6F (Mule 3010 Trans4x4)
KAF620J7F (Mule 3010 Trans4x4)
KAF620J8F (Mule 3010 Trans4x4)
KAF620K6F (Mule 3010 Trans4x4 Hardwoods Green HD)
KAF620K7F (Mule 3010 Trans4x4 Hardwoods Green HD)
KAF620K8F (Mule 3010 Trans4x4 Hardwoods Green HD)
KAF950-A1 (Mule 2510 Diesel)
KAF950-A2 (Mule 2510 Diesel)
KAF950-A3 (Mule 2510 Diesel)
KAF950-B1 (Mule 3010 Diesel 4X4)
KAF950-B2 (Mule 3010 Diesel 4X4)
KAF950-B3 (Mule 3010 Diesel 4X4)
KAF950B6F (Mule 3010 Diesel 4X4)
KAF950B7F (Mule 3010 Diesel 4X4)
KAF950C7F (Mule 3010 Trans4x4 Diesel)
KAF950D8F (Mule 3010 Diesel 4X4)
KAF950E8F (Mule 3010 Trans4x4 Diesel)
KL250-A1 (KLR250) (1978)
KL250-A1A (KLR250) (1978)
KL250-A2 (KLR250) (1979)
KL250-A3 (KLR250) (1980)
KL250-A4 (KLR250) (1981)
KLT200-C1 (KLT200) (1983)
KLT200-C2 (KLT200) (1984)
KLT250-C1 (Prairie) (1983)
KLT250-C2 (Prairie) (1984)
KLT250-C3 (Prairie) (1985)
KLT250-P1 (Police) (1984)
KZ1000-A1 (KZ1000) (1977)
KZ1000-A2 (KZ1000) (1978)
KZ1000-A2A (KZ1000) (1978)
KZ1000-A3 (KZ1000) (1979)
KZ1000-A3A (KZ1000) (1979)
KZ1000-A4 (KZ1000) (1980)
KZ1000-B1 (KZ1000 LTD) (1977)
KZ1000-B2 (KZ1000 LTD) (1978)
KZ1000-B3 (KZ1000 LTD) (1979)
KZ1000-B4 (LTD) (1980)
KZ1000-C1 (Police 1000) (1978)
KZ1000-C1A (Police 1000) (1978)
KZ1000-C2 (Police 1000) (1979)
KZ1000-C3 (Police 1000) (1980)
KZ1000-C4 (Police 1000) (1981)
KZ1000-D1 (Z1R) (1978)
KZ1000-D3 (Z1R) (1980)
KZ1000-E1 (Shaft) (1979)
KZ1000-E2 (Shaft) (1980)
KZ1000-G1 (Classic) (1980)
KZ1000-M1 (CSR) (1981)
KZ1000-M2 (CSR) (1982)
KZ1300-A1 (1979)
KZ1300-A2 (1980)
KZ1300-A3 (1981)
KZ1300-A4 (1982)
KZ1300-B2 (1980)
KZ200-A1 (1978)
KZ200-A1A (1978)
KZ200-A2 (1979)
KZ250-D1 (KZ250) (1980)
KZ250-D2 (CSR) (1981)
KZ250-L1 (CSR Belt) (1982)
KZ250-W1 (LTD Belt) (1983)
KZ305-A1 (CSR) (1981)
KZ305-A2 (CSR) (1982)
KZ305-B1 (CSR Belt) (1982)
KZ305-B2 (LTD) (1987)
KZ305-B3 (LTD) (1988)
KZ400 (1974)
KZ400-A1 (1977)
KZ400-A2 (1978)
KZ400-B1 (1978)
KZ400-B2 (1979)
KZ400-D (1975)
KZ400-D3 (1976)
KZ400-D4 (1977)
KZ400-H1 (1979)
KZ400-S (Special) (1975)
KZ400-S2 (Special) (1976)
KZ400-S3 (Special) (1977)
KZ440-A1 (LTD) (1980)
KZ440-A2 (LTD) (1981)
KZ440-A3 (LTD) (1982)
KZ440-A4 (LTD) (1983)
KZ440-B1 (1980)
KZ440-B2 (1981)
KZ440-D1 (LTD Belt) (1980)
KZ440-D2 (LTD Belt) (1981)
KZ440-D3 (LTD Belt) (1981)
KZ440-D4 (LTD Belt) (1982)
KZ440-D5 (LTD Belt) (1983)
KZ440-G1 (1982)
KZ550-A1 (1980)
KZ550-A2 (1981)
KZ550-A3 (1982)
KZ550-A4 (1983)
KZ550-C1 (LTD) (1980)
KZ550-C2 (LTD) (1981)
KZ550-C3 (LTD) (1982)
KZ550-C4 (LTD) (1983)
KZ550-D1 (GPz) (1981)
KZ650-B1 (1977)
KZ650-B2 (1978)
KZ650-B2A (1978)
KZ650-B3 (1979)
KZ650-C1 (Custom) (1977)
KZ650-C2 (Custom) (1978)
KZ650-C3 (Custom) (1979)
KZ650-D1 (SR) (1978)
KZ650-D1A (SR) (1978)
KZ650-D2 (SR) (1979)
KZ650-E1 (LTD) (1980)
KZ650-F1 (1980)
KZ650-H1 (CSR) (1981)
KZ650-H2 (CSR) (1982)
KZ650-H3 (CSR) (1983)
KZ750-B1 (1976)
KZ750-B2 (1977)
KZ750-B3 (1978)
KZ750-B4 (1979)
KZ750-E1 (1980)
KZ750-E2 (1981)
KZ750-E3 (1982)
KZ750-G1 (LTD II) (1980)
KZ750-H1 (LTD) (1980)
KZ750-H2 (LTD) (1981)
KZ750-H3 (LTD) (1982)
KZ750-H4 (LTD) (1983)
KZ750-K1 (LTD Belt) (1983)
KZ750-K2 (Canada Only) (1984)
KZ750-M1 (CSR Twin) (1982)
KZ900-A4 (1976)
KZ900-A5 (1977)
KZ900-B1 (LTD) (1976)
Z1 (Z1) (1973)
Z1-A (Z1) (1974)
Z1-B (Z1) (1975)

Tony wrote:

Installing the new seals didn't fix my leak. So I bought a whole new tach gear guide for about 38 dollars from Z1E. That fixed the problem. I should have done that a long time ago. The part number I got is PM81-2230.

Apparently there are least two designs of tach drive housings. The style pictured is different from the part# 92087 depicted in the Kawasaki.com parts diagram for 1983 KZ750 LTD.

So am suspecting that the Z1 model's seal would fit okay but not the Z1 model's housing.

EDIT -- see later post indicating that tach guide housing may indeed be fitted to either model.

[click on image for larger view]

Tony wrote:

Installing the new seals didn't fix my leak....

The old petrified seal is difficult to completely remove, as required for clean installation of the new seal.

Removal of the old seal is often tedious and a little time-consuming, with the need to use a dental pick or similar tool to get all of it out bit by tiny bit.

Magnifying eye-glasses under a bright light are also helpful in seeing down inside the housing where the seal fits.

i soaked my tach drive housing in caustic acid for a little while, it really helped to get out the old rubber.

Hi Patton,
The oem pic you posted is what I had. The one I posted is what I put in. I though it seemed to be an improvement over the original. So far, so good. (fingers crossed)
I had been looking at that oil leak ever since I got the bike and made a couple of attempts to fix it. I didn't try your suggestion though. Next time I will give it a try.