Leaking OIl Presuure Switch Housing

Removed the oil cooler and replaced the oil sensor housing with an OEM unit on my 1982 KZ1000J2. Also replaced the 2 larger O-rings, the smaller one, and the O-ring on the sensor itself. Crunched down the 2 bolts and for the first 20 miles yesterday everything was dry. Then, ut oh, started to leak again. Among other things, does anyone know why that 3rd small O-ring is used on the inside bolt hole and no O-ring on the other? Is there any other thing in that area where I might spring a leak? Difficult to see in there. Also, can't get a torque wrench in there with removing a bunch of stuff. Thanks.

That's enough to make you Grumpy!
If it didn't leak at first, then started again, maybe the o-rings you used were not correct? I put a thin coat of silicone seal, just a smear, on my o-rings. Rarely have any trouble. That 3rd small 1 around the bolt hole is an unknown to me, I looked and said WTF how about the other bolt? Anyway looks like practice makes perfect, you'll get it. Remember to clean it all off and recheck where the leak is, a small mirror and light might help. Some like to put powder then look for the wet spot. No fat lady joke!

A for real J bike? I have always wondered what one looked like.Nice scooter.bj

It's quite possible it's leaking around the brass nipple that the wire connector slides onto. I've seen that more than once

Thank you all. I think I will pull the housing and smear the O-rings with some oil compatible silicone and see what happens. Larry: Are you referring to the pressure switch itself? I hope it is one of these issues and not a leaking base gasket. That would be a HUGE bummer.

grumpy56 wrote:

Thank you all. I think I will pull the housing and smear the O-rings with some oil compatible silicone and see what happens. Larry: Are you referring to the pressure switch itself? I hope it is one of these issues and not a leaking base gasket. That would be a HUGE bummer.

Yeah! Fixing a leaky base gasket sucks. Apparently the picture of my bare frame isn't going to post.

Did you get the problem solved? If so where was it leaking?

Took it out for about a 15 mile ride yesterday and no leak, but I think the leak will re-appear when it gets hot on a longer ride. Bought some "black" Permatex to smear on the o-rings, but have not yet tried that yet. Will be my only option if (when) it starts seeping again. Still not sure where the leak is coming from, but eventually will find out (I hope).

I use spray on foot powder when troubleshooting an oil leak. It will wash off with some soap and water leaving no residue.