oil leak

[justin taylor]

Ihave an oil leak from the front left side casing(alternator cover),it seems to be dripping from where the wires come out at the bottom of the casing.Firstly what are the wires and secondly how do i stop the leak?Any advice will be greatly appreciated.

[Pigford]

Justin, this is the most common leak on a Zed
The wires are from the alternator, they pass through a rubber grommet which after time perishes & hence the leak
Best way is to replace grommet, available from Z power to name but one supplier. Or, remove casing ( tilt bike to right side as a little oil may tip out ) and thoroughly clean are with de-greaser (Gunk/Jizer etc). when clean & dry, use silicon sealer or good gasket goo, and re-assemble.
Good luck

[london calling]

Use a new grommet and a small amount of silicon sealant as it states in the Kawasaki workshop manual
Don't forget a new gasket as well.

[justin taylor]

Thanks for the help lads.Z Power sell an alternator cover grommet(part no 92075 alt)is this the one i need?What is the procedure to fit it?Thanks again

[london calling]

Justin,if you send me your address I can lend you one of my manuals with all the information you need.

[Steve S]

Justin,as per previous threads on this subject you may not be able to fit a new grommet without cutting the wires through it as there may not be a plug disconnect easily to hand,check the grommet first if its in good condition clean up,seal up and dont forget the new gasket.

[ROZZER]

The key to success here Justin is making sure that the wires/grommet are completely degreased and dry. Recently did our kids for him, degreased with cellulose thinners put silicon around wires/grommet (make sure you force silicon all around wires) new gasket and hey presto no more leak. Previous owner had tried to cure numerous times without success and told my brother it was 'just one of those things and all zeds do it'- utter rubbish, its all in the prep'.

[Steve R]

Fully agree with Steve and John. I bought a new grommett then did not want to cut the wires . thourhgly cleaned and dried it all then silicone sealant, hasnt leaked since!

[justin taylor]

Many thanks for all your help lads.When you say fit a new gasket do you mean the alternator casing gasket?Ihavent been in there yet so i dont know what i will find.Thanks.

[ROZZER]

Justin, New alternator paper gasket is what you will need and new grommet (may not need grommet if it looks ok as the silicon will seal if you are meticulous in prepping the wires/grommet) - Good Luck.

[rickman CRR]

Hi Justin,

I had a similar problem with my Z1. However I managed to reuse the original square grommet seal by buffing up the mating faces with emery paper, degreased it and applied a small amount of sealant with new alternator gasket.

You'll probably find the old gasket will stick and break up when you pry off the casing. Careful cleaning up of the facings with a blunt scraper will be needed before reassembly.

Take your time, keep it all clean. Good luck.

[Phil50]

I have to say (even if my is faulty) do not usesilicon sealer. It is not oil resistant. Better to use Blue Hylomar gasket sealer. Its used by Rolls Royce and it works. I have a bike problem but not one single oil leak. You can get it from most quality car spare shops. Good luck
regards