'82 kz1100 base gasket still leaks from left front corner

My base gasket replacement didn't solve my oil leak issue. Still leaks from left front corner, like it always has since PO owned it. I had recently replaced the four heavy O rings (oil galleys), base gasket, head gaskets, valve cover gasket, and four cam end caps. My highly regrettable mistake - due to budget no surface machine work was done. Even though I'd checked it all out with a straight edge. Not sure on which surface should be machined? Case or bottom of jugs? Or both? Much thanks in advance. Thanx! Gary
 

Did you use OEM gaskets and seals, and make sure the surfaces were perfectly clean?

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My base gasket replacement didn't solve my oil leak issue. Still leaks from left front corner, like it always has since PO owned it. I had recently replaced the four heavy O rings (oil galleys), base gasket, head gaskets, valve cover gasket, and four cam end caps. My highly regrettable mistake - due to budget no surface machine work was done. Even though I'd checked it all out with a straight edge. Not sure on which surface should be machined? Case or bottom of jugs? Or both? Much thanks in advance. Thanx! Gary



 

Maybe time for an external oil feed mod?!?!

kzrider.com/forum/2-engine/608211-external-oil-feed-to-head

 

Had the same thing happen once, but that was before I replaced the old stretched out stock cylinder studs with a heavy-duty set by APE.  Several head changes since, and there are still no leaks with 42 ft. lbs. of torque on the head nuts.

wrote:

Did you use OEM gaskets and seals, and make sure the surfaces were perfectly clean?

Yes I used only OEM stuff from Z1. Yes, a rather tedious process but yes surfaces were clean. I hope not, but may have been a bit too aggressive on that corner while trying to remove stubborn gasket material, I dunno. Can underside of jugs be re-surfaced? Thanx 

wrote:

wrote:

Did you use OEM gaskets and seals, and make sure the surfaces were perfectly clean?

Yes I used only OEM stuff from Z1. Yes, a rather tedious process but yes surfaces were clean. I hope not, but may have been a bit too aggressive on that corner while trying to remove stubborn gasket material, I dunno. Can underside of jugs be re-surfaced? Thanx 

I don't think Z1 sells OEM gaskets.  Just checked the base gasket they sell for the 1100 and it's all of $6.99 and states "equivalent to OEM".  NOT!

I believe the gaskets and seals were OEM,   ...so please let me rephrase, they weren't the green athena (sp?) brand that I'd read to stay away from. I'll look for my invoice and give ya the part numbers to confirm. Thanx again.  Gary 

Ok found the invoice, it was upper end kit Part # SU609-0847

I had this same issue a few years back. I traced it to a stripped thread on one of the crankcase studs - fixed with a timesert. 

also check your studs aren’t bottoming out the head bolts fooling you into thinking the whole lot is tight, a set of the taller APE stud bolts fixed this for me too, leak free for 25k since. 

Thank you! Yes, tracing down small oil leaks can really be challenging, often times it can seem so misleading.