Hi Guys & Girls,

I have been away for awhile & finally got around to taking my 07 KLX250 out of storage.

I didn't ride it at all last year & while it was in storage, it seemed someone F#@ked with it
(The clutch was out of adjustment & oil all over the floor)
I never took the mileage down when I stored it in my brothers shed so I can’t tell if some one rode it or what.

What I found was the crankcase was full of oil/gas & someone turned the fuel on & the float stuck flooding the motor. When the bike was parked it had a full tank of fuel with stabilizer & the fuel valve was shut off & engine run till it stalled.

I drained the crankcase, replaced the filter & oil & drove her home. She has been parked ever since.

Last week I put in a new battery, turned on the fuel & she fired right up. Everything looked & sounded fine till I see a steady drip of oil coming from the left side cover where the electrical wires come out of.

Right now my bike has a total of 800 miles since I bought it new & wish I had the extended warranty. I hate doing my own repairs but depending on what it is I can do it myself.


Any ideas what is wrong?

 

I trailered the bike to my dealer; the mechanic said that the rubber plug that the wiring from the stator passes thru is dry rotted cracked & looks like someone gave it a yank.

The rubber plug cannot be replaced & they won't RTV it due to "liability reasons" Due to time constraints, I am replacing the stator.

I should have the bike back in a week.

 

That stinks... my guess would be that the gasoline was not friendly to the rubber. Hopefully it wont affect any other seal areas.. The fuel overflow happened to my bike as well... made me sad. :P Hope it comes together good for you.

 

Any ideas what's wrong? Uh your brother needs a beat down, or at least give you some answers to what the freak happened!!! You should have locked the steering and threw on a back up cable around the rear wheel! That's just not right. Why can't you RTV the plug? That makes no sense. The dealer is full of it! Stinking stealerships. GRRRRRR

 

"Can't be replaced". Hmmm, well somehow that plug was installed and we humans are pretty clever about taking things apart and putting them back together. So the whole side cover needed to be replaced?

 

I believe those plugs are sealed around the wires, so I can see them not having the plug as a replacement piece cuz you'd have to cut the wires and feed them through, but then it wouldn't be a good seal ... but it still sucks to buy a whole stator just for the rubber boot. I'd probably try some of that high quality honda silicone head gasket stuff before I bought a new stator, but I've made expensive purchase to make a fast repair before too, all my sympathy and +1 on what's up with someone messing with your bike... the float obviously wasn't stuck when you ran it out of gas :P

 

I think it's the stator that's being replaced, not the side cover. The rubber sealing plug that wraps around the stator wiring is more complex than one might think, but I'd be tempted to experiment with injecting some good, quality silicone in and around those wires and the rubber body to try and seal it up. The hardest part to seal is where those 4 wires go through the sealing plug independently. The outer part of the plug can probably be sealed fairly decently.

 

Speaking to one of the guys on the phone from the dealer, he said if it was him, he would take it apart,degrease it all & reassemble with black RVT & let it sit 24 hrs before puting it back in service & seeing how it holds up.

I parked the bike in my brothers shed with a full tank of gas w/stabelizer, ran the engine till the carb was dry. I left the key with him in case he needed to move it to access his mowers or Harley.

I didn't expect in my wildest dreams to find the fuel in the on position, crankcase full of gas/oil & my clutch lever flopping in the breeze.

When speaking to the mechanic about the cost, he said the time involved is minimul, the parts are what I am getting raped for. 10% off sugested retail. I should have ordered them from MrCycle & had shipped direct to the dealer.(probally would have had them sooner too)


Learned a few valueable lessons. Don't leave bikes under cover outside as the elements play hell on them & not to store where others have access to them.

 

there's a product that's made to seal old windshield rubber, the name escapes me but I have a tube at work, I can look.

It flows as thin as water and penetrates well before it sets up, has worked on old dry window rubber, bet it would work here.

 

Got my bike back today!

No more leaks,fluids all topped off. The chain,throttle,clutch cable lubed & adjusted.

The best part is they have added stand off wire looms off the cover bolts to keep the wires secure.

I enjoyed the ride home today but realized something. I either need to drop weight to get back to 200# or a Kustom Kraft 330 Big Bore kit OR maybe both!