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Discussion Starter · #1 ·
Hi all,

I'm new to the forum and would like to say hi as well as pick your brains if I may.

While riding mid-range rpm all is well once i twist the grip moving towards the top of the rev range oil bursts out somewhere on the right side of the bike. I cant find a thread on this. As well as the bike shop installed a surge tank of sorts which seems ok barring the terrible mod to the oil filler cap.

Any insight would be greatly appreciated.
 

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Discussion Starter · #3 ·
Will upload pics if my efforts today failed as I've run a couple pipes and will see if it works. Also to answer your question the bike hasn't been dropped at all. I've tried placing the gopro near where I thought the oil had been shooting out of but I was wrong. So just putting the plastic back on and will see if I take it for a run tonight or tomorrow morning and if I have failed I'll place everything the way I received it from the bike shop after their pathetic attempt to remedy this issue.
 

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Discussion Starter · #4 ·
Just a pic to show you what I did just to test. So what your looking at is the oil filler cap that was pretty much butchered by the guys in the shop so what they did was drill a hole in the filler cap and run a hose to a surge tank from which one hose returned to the air box and another to the top of the crank.
 

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Holy hell! I've been on the Internet a long time, but this is something I haven't seen before. To say you bike is butchered is not an understatement. Wow. :eyecrazy:

On a stock motor, the crankcase is connected to the airbox through a breather tube. That vents the crankcase to atmospheric pressure so that the pistons move up and down relative to each other, the air can move back and forth. The crank flings the oil around in there and the windage of that creates an oil mist. Vent that back to the airbox so that it gets reingested into the motor and burned up. No big deal, that's what it's for.

The problems start to happen when the combustion pressure gets passed the piston rings and pressurizes the crankcase. In a perfect world, that will never happen since the rings should seal 100%. In the real world they don't. Some blowby will create an over-pressure condition, air and oil film go to the airbox, and everything is fine. Too much blowby on poorly sealed rings and the motor runs like crap and you fling oil everywhere. Not good.

If you're blowing oil overboard, you need to do a leakdown test on the motor to see what the condition of the valves and rings are. Then, replace that oil cap with a sealed one. There's no reason to vent the motor from the clutch basket. Ugh. That stupid "surge" tank should be hooked to the OEM crancase vent opening on top.
 
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Discussion Starter · #6 ·
Absolutely butchered and thank you guys for the response. What I will do is get to Kawasaki tomorrow replace oil cap see if they could run the tests there and then.

Again much appreciated.
 

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Just a pic to show you what I did just to test. So what your looking at is the oil filler cap that was pretty much butchered by the guys in the shop so what they did was drill a hole in the filler cap and run a hose to a surge tank from which one hose returned to the air box and another to the top of the crank.
Is that where the air goes in??:dontknow:

I Can always tell when Shervin has touched a bike.
 
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Absolutely butchered and thank you guys for the response. What I will do is get to Kawasaki tomorrow replace oil cap see if they could run the tests there and then.

Again much appreciated.

Good. If they can do a leak-down test then that should answer some questions on the status of the motor. A compression check won't really tell you much in regards to this issue. A new cap should seal everything back up which will be a start.



What's interesting is what the previous mechanic was trying to do with it all? Were you getting too much oil in the airbox so they vented it to that surge box? That would indicate blow-by on the rings also and an external collection container is a bandaid fix. Or was there another reason they did this "mod"? Those are the questions to ask....
 

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Good. If they can do a leak-down test then that should answer some questions on the status of the motor. A compression check won't really tell you much in regards to this issue. A new cap should seal everything back up which will be a start.



What's interesting is what the previous mechanic was trying to do with it all? Were you getting too much oil in the airbox so they vented it to that surge box? That would indicate blow-by on the rings also and an external collection container is a bandaid fix. Or was there another reason they did this "mod"? Those are the questions to ask....
My first thought exactly!

WHY???!!!! :idea:

Would love to hear his explanation.
 

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That "fix" for the cap is a pretty good thing if it was implemented to get you home after a crash a long way from home. Otherwise, WTF!!! Duct-tape?:crackup:
 

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That "fix" for the cap is a pretty good thing if it was implemented to get you home after a crash a long way from home. Otherwise, WTF!!! Duct-tape?:crackup:

:spit: True statement! I was actually surprised they used Duct-tape instead of Duck-tape. They should just throw some Flex Tape on it to seal it all up. That shit will seal anything! :idea::crackup:
 

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That "fix" for the cap is a pretty good thing if it was implemented to get you home after a crash a long way from home. Otherwise, WTF!!! Duct-tape?:crackup:
Id have just JB welded that fuker and be done! :grin2:
 
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Discussion Starter · #13 ·
To answer all the comments the twot at the bike shop did this as a permanent fix which would make any Kawasaki lover cringe inside. Anyway took the bike for pressure testing and all came back within spec. So searching the web like a porn perve I found a bunch on the kleen air mod which I invested in and installed.

This seems to have sorted the issue. So from crank breather straight to where the pcv is (pcv removed) installed brass T piece x2 one close to the crank and from that T piece to an oil breather filter routed through to under my rear seat. Also on a side note I too struggled with the infamous rattle... long story short the culprit was the fuel filler cap, the key flap to be specific.
 
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