clutch cover leaking tranny

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clutch cover leaking tranny

Postby Jeff j » 10:58 pm Nov 10 2017

hey guys, i have just recently purchased an 06 kdx200, i'm having a few problems with tranny oil coming out of the middle-top rear side of clutch cover

with this being my first owned bike i have not a clue what is going on here and any help would be much appreciated :supz:
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Re: clutch cover leaking tranny

Postby doakley » 11:19 pm Nov 10 2017

Drain fluid, remove the cover, clean all old gasket material and replace gasket. Refill with fresh oil and try her again. Oh yes, look for damage to the cover while it is off.
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Re: clutch cover leaking tranny

Postby Jason » 12:13 am Nov 11 2017

Welcome to kdxrider.

Is there silicone sealant on it, or a genuine Kawasaki gasket?

doakley has provided an excellent response.

Check to be sure the bolts are stock (metric) and someone did not half ass it and throw in an SAE bolt.
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clutch cover leaking tranny

Postby thirdgenlxi » 01:14 am Nov 11 2017

Also keep in mind there is an outer clutch cover (the little round one), and the inner clutch cover (the whole big side cover that the outer cover bolts to). If it's just the outer cover that's leaking than it should be a super easy fix, following what was posted above. But if it's the inner one, then that's quite a bit more involved
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Re: clutch cover leaking tranny

Postby Jeff j » 01:51 am Nov 11 2017

its just the small one the first one, and yes its been well looked after by the looks of things, its the factory gasket
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Re: clutch cover leaking tranny

Postby bufftester » 02:01 am Nov 11 2017

Could be that it just failed, gaskets do that sometimes. Regardless, take it off, clean the mating surfaces, inspect for any damage, and install a new gasket and properly TORQUE the cover back on.
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Re: clutch cover leaking tranny

Postby Jason » 02:11 am Nov 11 2017

in a star pattern. :supz:
Thank you, Julien D for all your hard work!
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Re: clutch cover leaking tranny

Postby Jeff j » 03:33 am Nov 11 2017

What do you mean torque it on?
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Re: clutch cover leaking tranny

Postby Jim B » 04:09 am Nov 11 2017

Jeff j wrote:What do you mean torque it on?

Tighten the bolts the correct amount, using a torque wrench. (Arguably not 100% necessary, but not a bad idea if you have a good torque wrench.)
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Re: clutch cover leaking tranny

Postby Timtee » 07:27 am Nov 11 2017

Jim B wrote: (Arguably not 100% necessary, but not a bad idea if you have a good torque wrench.)


If you own a bike and will be doing the maintenance on it - an inch and foot torque wrench are must haves. With all the aluminum on the bike it would be too easy to strip out threads. And critical parts like clutch hub, swing arm and axles nuts, you want those torqued correctly.

As tempting as it is to goto HF, buy quality torque wrenches.
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clutch cover leaking tranny

Postby ohgood » 09:17 am Nov 13 2017

Jeff j wrote:hey guys, i have just recently purchased an 06 kdx200, i'm having a few problems with tranny oil coming out of the middle-top rear side of clutch cover

with this being my first owned bike i have not a clue what is going on here and any help would be much appreciated :supz:



the black rtv in a tube will seal that up fine after you clean up the old gasket.

throw the bike over on its left side and you won't get any spillage when you pull the cover off.

if you're scared of tightening fasteners on motorcycles, or don't have any experience with tools, check the torque specs several times and apply a LOT of common sense..... when the spec is wrong and people blindly follow it.... things strip.
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