Leaking Shift Mechanism Cover
 

This is going to be the third attempt to reinstall the shift mechanism cover on my 2018 KLX 250, after replacing some parts, I reinstalled the cover using the original gasket with some liquid gasket material. I didn't drain the oil, merely laid the bike on its right side. I noticed that there was some weeping going on in that area, so decided to buy a new gasket and swap this out. Now this thing is leaking more than it had been. I am going to take another run at it this evening. I will use some liquid gasket as well as the newer gasket. I see that is calls for 87 in# of torque which I can do, except for the nut on the lower rear of the cover, just going to ball park that. I'll leave it on its side overnight, so gasket material will have more of a chance to set up, and see what happens.

Did you ever get this sorted?
 

I also have a 2018. I just replaced the same cover gasket on mine and now it’s leaking? It wasn’t leaking before. I scraped and cleaned both mating surfaces and tried attaching it dry. Now I have added some RVT black and re installed it. I will see how it is tomorrow. Mine is leaking right on that nut, but it is for sure at least 87 in-lb. anymore I’m scared I will snap it.

Hope you added some on the threads of the nut, are you sure it isn't the shift shaft seal? I ordered a shift shaft seal and it is sitting on a shelf, cheap insurance. The biggest pain of this whole project it pulling the sprocket. You didn't mention why you pulled it in the first place? I had an issue with it jumping out of 5th or 6th gear, and I was hoping by changing out the "shifter centering pin", it might solve the problem. So far it seems to have. I have 2 Kawasaki's, this KLX and a Versys 650 and I will say, that neither shifts as well as the Yamahas I have had over the past 50 yrs, in particular the 1st to second, I miss those far too often.

It isn’t leaking from the shift seal. It is leaking from the gasket, either at the nut or above the nut and dripping down to the nut. I did not pull the sprocket, just disconnected the chain from it, you can slide the cover in and out with it still on. I had to retap my oil drain plug so I pulled to cover to collect the shavings. Just confirming you did get yours to quit leaking right? With the new gasket and RTV?
Thanks for the reply!

I can't imagine removing that cover with sprocket installed, you have to do some wriggling around to get that cover installed correctly. That stud with the nut on it is a big ? why didn't they just use another screw or bolt. My cover doesn't appear to be leaking at least not anywhere near what it did. I didn't use any liquid gasket just the paper gasket. But I would have added some kind of liquid gasket had it still be leaking. I did this without draining the oil, by laying it on its right side. Believe I may have left it overnight laying on that side, some of this liquid gasket takes a bit of time to set up. Good luck.

On attempt number three. Filled it up with oil last night and had a very minor leak with the RVT and new gasket. It was nowhere as bad as before. Before it was a drip every second, now it’s like a drip a minute. It appears to be above the nut, maybe the screw? I took it back off and inspected the paper gasket and I can see the indentation all the way around the gasket except in between the nut and screw. I cleaned it all again and added RVT to just that area. Now it’s sitting on the side, will try again tonight. If it doesn’t seal again I might go back to the old gasket it’s still in good shape, maybe my new one is just bad??