Hey all, I decided to just start a thread for my XT600 Tenere 34L since it's got a few issues and I figure it will be easier than having a bunch of threads for each.

Anyways I'm prepping the bike for a trip from Ghana to Morocco then onto Europe via the inland route. The bike and I are currently in Ghana so my access to new parts and tools is pretty limited, but I do have a fair amount of spares and other things I'd need to prepare. Many thanks to David Lambeth for all the advice and some spares.

My first issue is a persistent but somewhat slow oil leak originating somewhere near the front sprocket. It doesn't leak when the oil is cold, only hot. I cleaned the area and finally spotted a first drop. It is there on the bolt hole directly underneath the sprocket. It appears a PO had a chain break and repaired the case there as there's white goop stuff everywhere. Even on the crankcase drain bolt (which you can barely see in the photo) preventing me from draining from there. Could the leak be coming from beneath the sprocket or from the repaired case?

Second, despite my careful tightening and knowing that the oil filter cover threads can be stripped easily, it seems I stripped the oil filter drain bolt threads. Is there anything I can do to stop the leaking until I can find some method of repairing the thread? There are no hardware stores that I know of here so I can't just run down and buy some helicoil or something like that. I may get some shipped from the States since I have a GPS being sent by my ever so kind parents. What is the size of the bolts? M6 x ???

PS I know the chain and sprocket and everything is really dirty and need replacing. I have all those things I just want to figure out this oil leak first!

Thanks for any advice!

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XT600Z Tenere 34L
'75 DT400, '67 YR1

certainly add a new sprocket and chain kit to your shipping list, that worn front sprocket with hooked teeth must have killed the chain by now. it's a breakdown waiting to happen and could could crack your crank cases too when it does. just a new chain wil be destroyed soon by that sprocket

leak could be something as simple as the oil seal behind the sprocket.

it can be pulled out with a hooked tool without dismantling the motor if it leaks, dismount the sprocket to check

many times the threads continue deeper in the hole after the stripped ones. take a slightly longer bolt and see if catches something, dont overtighten

Remove the sprocket and clean the area around the front sprocket until it's immaculate.

Prop up the bike so it's back wheel is free spinning and let the bike warm up.

Engage a gear and let the counter shaft spin.

Check for oil.. It's most likely the countershaft seal. (Behind the sprocket)

If its not then now the bike is clean, you can see what it is.


If you've stripped the threads on the oil cover then a repair is pretty much your only safe option. Don't bodge it with sealant when you know the threads aren't good because you'll only get 20 miles down the highway and have oil pissing all down the side of your bike, your pants and your rear wheel... Totally ruining your day.

The threads are most likely a M6 x 1.0 (but I'm just guessing.. Find out)

You will need a heicoil kit which includes:

Drill bit specific for the thread Tap, tap for the helicoil size, helicoils, inserting tool, tang punch.

You will also need a tap driver for the size of tap and a power drill. Buy a selection of lengths of helicoils. A set of drill bits is useful too.


I'm also certain that there will be workshops in Ghana who can repair threads.


If you REALLY REALLY (last resort) have to bodge it then using a slightly longer bolt (3-5mm longer) with a lot of thread lock on it can work. The thread depth in the casing is usually longer than the bolts. It's a case of trial and error though.

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Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

Yep, I've already got the chain and sprocket set here in Ghana that I bought from David. I wanted to find and fix this oil leak before I changed the set because it gets oil everywhere once I'm riding! I'm also not doing any long distance or hard riding until I get this set changed. Just some short rides around the city for the most part.

Thanks for the advice, I've got a new oil seal that's under the sprocket on the way from Yambits. I've also got a helicoil kit and the other things needed from Amazon going home to California to be sent to me by my dad.

Is there any issue with not being able to get off that crankcase oil drain bolt? If I change all the oil in the tank and use a new filter will it be enough?

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XT600Z Tenere 34L
'75 DT400, '67 YR1

Its not ideal but not the end of the world. Obviously dont put in the full amount of oil in when you change it..

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__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

good advice posted by others above...follow it.


See the small wire running below the sprocket with a Phillips head screw (as seen in your picture). As Ted suggests clean the entire area....The bit the wire is screwed into is a neutral sensor that activates the neutral light on your dashboard. I have had this sensor leak on my XT....it is a bolt like piece that is hollowed out and the sensor is imbedded in there from the factory with epoxy. After years and years of service sometimes the epoxy begins to fail and oil leaks.


Please note.... It typically does not leak at the threads...Tightening the sensor in the case is not the solution....The epoxy starts to fail and a leak begins between the metal outer and the epoxy inner of the sensor. Replacement is required or more epoxy can be applied in an attempt to repair if replacement is not an option.


Best way to check for this potential leak spot is as Ted recommends...clean everything and test.


Good luck


Pawlie

Thanks for the advice. I'll check that out too.
The oil seal came so I got the rear wheel and sprockets off the other day. Wasn't able to break the chain as of course I forgot my chain breaker somewhere else in Accra but now I have no moto to go and get it with. Oops. The old chain is shot anyways so I'll figure out some other way to get it off.

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XT600Z Tenere 34L
'75 DT400, '67 YR1

So I have some good news and some bad news. Good news is that the sprocket seal is definitely leaking so I will replace that and hopefully solve that. Yay!



The bad news is that there is a second worse leak coming from above.



It's coming from the area between the circular dimple and the white epoxy stuff where the cover and engine case meet.
Is this one possibly just because it needs a new gasket for this left side cover? I have a full gasket set if so..

Edit: I forgot to mention there doesn't seem to be a leak from the neutral switch at the moment but I'll keep an eye on that



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__________________
XT600Z Tenere 34L
'75 DT400, '67 YR1