Question about 2002 kawasaki ZZR 250

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Oil leaks from breather box

There is a small hole on the left hand side bottom of breather box {air filter box} is it supposed to be there.oil leaks out when on side stand

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  • Anonymous May 18, 2009

    or there is to much oil in the sump the best way of alimanating this is to drain all oil remove filter to ensure there is no oil left in the sump then replace filter and replenish with about 1.6 ltr of oil as there will be some oil left in the head. if the problem persists have a compresion test carried out but the little zzr engine is more known for ruining its big ends and snapping rocker arms than kaning its rings ive had one drop valves and a dealer said that that is more or less un heard of

  • Anonymous Mar 14, 2014

    Is there supposed to be oil inside left case cover..been dropped on side and now has tiny hole in case. is there even supposed to have oil in there?

  • Anonymous Mar 14, 2014

    Rear diff leaks oil from breather

  • Anonymous Mar 15, 2014

    oil leaking from breather

  • Anonymous Mar 16, 2014

    breather box filling up with oil on 650 Quest

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  • Master
  • 404 Answers

Hi!
From your brief description It sounds like you are experiencing Crank Case pressure build up.
I presume your ZZR is of High mileage or possibly previous owners havn't serviced it regularly.
The problem being the compression Piston Rings wear and allow Blow Back gasses into the crank case there by building up pressure, this in turn sends an oil film up the breather tube to your air box resulting in your problem.
You could try an oil & filter change (Synthetic) Top jolly with maybe an additive plus similar for the fuel i.e. Red-Ex or similar, it may help but I doubt a cure.
If you want you could extend the breather pipe away from the box into a drip can or similar, be sure to filter it as you don't want to get contamination down in the cases.
Hope this sorts it for you?
Please press the Blue Button for appraisal of my FREE! Effort.
Thank You! & Good Luck.
Paul 'W' U.K.

Posted on Mar 05, 2009

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1 Answer

Way to much oil coming out air cleaner


Oil coming out of the breather is natural and normal, with basically no way to stop it. There is about 1/2 qt of oil in the bottom end of an engine, as the pistons travel downwards, the air that is under them is being pressurized and is vented out of the engine by a rotary breather valve in the case. The air picks up a small amount of oil from the bottom end as it leaves, then the air/oil mist is vented either into the air cleaner (EPA Regulations) or best if vented to the atmosphere. NOTE: WORN RINGS ALLOWINGS EXCESSIVE COMBUSTION PRESSURE BLOW-BY WILL MAKE THIS SITUATION EVEN WORSE. When it\'s vented into the air cleaner, some if it recirculates into the engine and out the exhaust, the rest saturates the air filter and then eventually gets blown all over the side of the bike. The best way to vent it, is to route a hose from the breather system down to the frame between the engine and trans, run it under the bike on the right side, point the hose down to the GROUND and zip tie it in place.



To stop the leaking breather BOLTS...remove them, and use brake cleaner to completely remove all oil from them, the washers, brackets and threads in the head. Use liquid teflon thread sealant on the bolt threads, and a light film of black rtv on the faces of all the washers and brackets, install everything, let sit for 24 hours, then ride.......if done properly and rtv is CURED, it won\'t leak.

Also note that most HD\'s with the oil tank mounted under the seat and are left sitting for a couple months will PUKE oil from the breather, this is due to the gravity....the oil will slowly seep through the oil pump and collect in the bottom of the crankcase and get blown out the breather when the bike is started.



Also:

The HD engine design is a dry sump engine, but there is always a small amount of oil in the bottom end....THIS IS WHERE THE OIL MIST COMES FROM......it is "possible" for too much oil to give your symptoms, if you have too much oil in it, the oil tank is vented back into the cam compartment, causing excessive oil build up in the bottom end, if this were the case, the oil would be PUKING from the breather, because the oil pump does not have the ability to scavenge that much oil back to the tank that quickly, which in this event, the tank doesn\'t have the room to store any way.

But even so, this is an all too common question and the symptoms are seen on almost every HD on the road.....could it be possible that EVERY HD has too much oil??? In my answer, I tried to explain WHY this happens.....even with or without too much oil.....this will still happen.

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My 2009 1200L sportster leaks oil out the air filter every 2000-3000 miles.It blows onto my exhaust and higher up. I've had my rocker boxes replaced(warranty issue) THREE TIMES- could this be rela


The problem is the the air breathers inside the rocker covers. Sad to say,but nearly all of them do this. One solution is to take off the air filter cover. There should be two bolts..(one on each side of the inside of the housing) that SHOULD have hoses hooked to them. If they do not have the hoses hooked to them,then that is your problem. See,these bolts are hollow,and have a nipple on the ends of them. These allow the top end to "breathe",a crankcase pressure relief if you will.Anyway,..these nipples are SUPPOSED to have a small hose on each of them,that re-direct the oil/crankcase pressure, into the carb/throttle body,which eliminates the oil running into your air filter housing.Check to make sure they are in fact there,and let me know what you find.

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I had this problem on my 2011, I called a dealer and asked about it. I simply overfilled the oil. Supposed to check the oil level when it's hot not cold. Idle it for 15 min then check the oil level like the manual says.

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My 1982 yamaha seca 650 has too much oil pressure I just bought it and it is blowing the oil cap off the person that I bought it from drilled holes in the cap now it sprayes oil out of the holes any idea...


There should be an oil breather tube on the left side of the engine leading the airbox. Make sure it's there and cleared out. If the previous owner removed the air box and put on pod air filters, he may have plugged the breather line.

Also, check your oil level. Use the sight glass - only when the engine is off and the bike is level on the center stand. The sight glass is on the clutch cover - right side, bottom of the engine. There is a mark on the glass showing the correct level.

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Revtech 110 blowing oil out the air filter, I sent my bike in for its first service (1000 Miles) and since the service the motor keeps spewing oil out the air filter... oil level reduced as i thought...


Oil coming out of the breather is normal on these engines by the way of design, with basically no way to stop it. There is about 1/2 qt of oil in the bottom end of an engine, as the pistons travel downwards, the air that is under them is being pressurized and is vented out of the engine by a rotary breather valve in the case. The air picks up a small amount of oil from the bottom end as it leaves, then the air/oil mist is vented either into the air cleaner (EPA Regulations) or best if vented to the atmosphere. When it's vented into the air cleaner, some if it recirculates into the engine and out the exhaust, the rest saturates the air filter and then eventually gets blown all over the side of the bike. The best way to vent it, is to route a hose from the breather system down to the frame between the engine and trans, run it under the bike on the right side, point the hose down to the ground and zip tie it in place...Be sure to point the end of the hose down & away from the tire.
If your breather bolts start to leak oil...remove them, and use brake cleaner to completely remove all oil from them, the washers, brackets and threads in the head. Use liquid teflon thread sealant on the bolt threads, and a light film of black rtv on the faces of all the washers and brackets, install everything, let sit for 24 hours, then ride.......if done properly and rtv is CURED, it won't leak...
Also note that most HD's with the oil tank mounted under the seat and are left sitting for a couple months will PUKE oil from the breather, this is due to the gravity....the oil will slowly seep through the oil pump and collect in the bottom of the crankcase and get blown out the breather when the bike is started ...

Good luck...i hope this helps

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1 Answer

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1 Answer

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Rick, since 1994, Harley has used what we call a "head breather" system in that the crankcase breathers are located in the heads. This was done in an effort to reduce the amount of oil that gets into the air filter. In earlier case breather model engines, the oil would pour into the air filter if the bike had been sitting for a few months. Prior to that, the bike would "puke" what looked like a quart of oil on the ground below the bike when first started after a long period of sitting.

If you'll remove the air filter cover and element, you'll see that the large bolts that hold the breather onto the heads are hollow. Inside the rocker boxes, there are small rubber "umbrellas" that are opened and closed by crankcase pressure. These are designed to allow your engine to breathe without an excess of oil being blown out. Still even though this system is better, a little oil still gets into the air filter. You can either keep this cleaned out or you can replace the "head breather" systems with an aftermarket system that changes the location the system exhaust crankcase pressure from. Also, you can change the "umbrella" seal and put in new ones. It isn't that difficult to do on the front head. The rear head can be tricky since there isn't much room to get to the bolts to take the rocker box cover off. The umbrella seals are located in the center section of the rocker box cover.

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