Oil leaking out of #2 exhaust header!

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17 Aug 2009 18:17 #314661 by Skonnie Boy
Oil leaking out of #2 exhaust header! was created by Skonnie Boy
I am resurrecting a kz650 and everything seemed to be going well. after adjusting the carbs, i started it up and the engine sounded beautiful BUT oil is dripping out of the #2 exhaust header at a pretty good rate. any idea where to begin to diagnose the problem?

'77 kz650C

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17 Aug 2009 18:43 #314663 by mzandmz
Replied by mzandmz on topic Oil leaking out of #2 exhaust header!
I heard theres oil passages near the exhaust ports? Maybe a crack where a stud goes into the head from the ehaust flange bolt? Does it start running funny when it starts leaking. Hows the plug look on number#2, Just Ideas. Someone will help you soon.

New to Family, 1979 KZ440 LTD

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17 Aug 2009 18:43 #314664 by bigkaw815
Replied by bigkaw815 on topic Oil leaking out of #2 exhaust header!
Exactly where is the leak coming from? Make sure its not coming from your valve cover.

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17 Aug 2009 19:43 - 17 Aug 2009 19:45 #314677 by Skonnie Boy
Replied by Skonnie Boy on topic Oil leaking out of #2 exhaust header!
it is actually dripping down the outside of the #2 exhaust pipe from the bottom.

'77 kz650C
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Last edit: 17 Aug 2009 19:45 by Skonnie Boy.

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17 Aug 2009 20:44 #314683 by bigkaw815
Replied by bigkaw815 on topic Oil leaking out of #2 exhaust header!
Would you take detailed pics of your engine and post them?

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17 Aug 2009 22:45 #314702 by TerryK
Replied by TerryK on topic Oil leaking out of #2 exhaust header!
Not too familiar with the 650s but does it have a tach drive cable like the big boys?

1977 KZ1000
GSXR swingarm and rear brake
WM6 rear Akront rim
Wiseco 1075c pistons
33 smoothbores
stage 3 Web Cams
Head porting
Dyna S ignition
Lockhart oil cooler
Wiseco header



1980 Z1R drag bike
1200cc
38 Flatslides, .
500' cams
7" slick
Dyan 4000 SP ignition
etc

Ontario, Canada

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18 Aug 2009 06:12 #314748 by Skonnie Boy
Replied by Skonnie Boy on topic Oil leaking out of #2 exhaust header!
Tach cable goes in above the #3 and #4 exhaust port. I'll take some pics and post. Have seen similar posts where blown gaskets were the problem. It would be swell if that was the problem, though I think its more than that. I'll get the headers off, take some pics and report back. Thanks, guys.

'77 kz650C

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18 Aug 2009 10:52 #314823 by Skonnie Boy
Replied by Skonnie Boy on topic Oil leaking out of #2 exhaust header!
Warning, some of these aren't pretty. Here's some up close and personal pics of the #2 exhaust port. From the first pic it seems the oil is coating the inside of the port pretty good. From the second pic, it looks like the gasket between the cylinder head and cylinder is intact, maybe even original. Neither pic seems to show a leak coming from the exhaust header bolts, though oil has covered the bottom one. The oil is likely coming from the cylinder itself.

So, am I looking at a new piston, piston ring(s) or piston sleeve? I'm guessing the only way to definitively know is to dig in. Thoughts?

'77 kz650C
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18 Aug 2009 10:53 #314824 by Skonnie Boy
Replied by Skonnie Boy on topic Oil leaking out of #2 exhaust header!
Here's the 2nd pic.

'77 kz650C
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18 Aug 2009 10:54 #314825 by mzandmz
Replied by mzandmz on topic Oil leaking out of #2 exhaust header!
compression check. check plug for fouling. leak down check.

New to Family, 1979 KZ440 LTD

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18 Aug 2009 11:17 #314829 by Skonnie Boy
Replied by Skonnie Boy on topic Oil leaking out of #2 exhaust header!
Its a new plug so there's a hint of soot on the tip, but the threads are coated in oil.

Compression tested the other day. All seemed well within range.

#1 - 105psi
#2 - 100psi (110psi upon retest)
#3 - 120psi
#4 - 110psi

Had the bike running in the garage for all of 5 minutes before the oil leak became apparent. It was a sizable amount, not a trickle. Made a baseball-sized puddle on the floor!

On the bright side, the ignition wire patch on #2 works and the bike sounded great after the carb synch. Little victories, little victories...

'77 kz650C
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18 Aug 2009 11:56 #314831 by mzandmz
Replied by mzandmz on topic Oil leaking out of #2 exhaust header!
Got to be leaking from outside or inside near head? your compression is little low for all cycl. none way low showing concern from oil blowby, plug would be oily around the electrode. If there seems to be alot of oil it has to be a leak from ??? we dont know. I hope you get an answer soon. Clean it with carb cleaner and after dry start the bike and have some eyes all around to watch for the trail to start. Best of luck. Over and out.

New to Family, 1979 KZ440 LTD

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