New-gen engine in Pre-gen frame. Oil leak under exhaust ports.

AFazakerley · November 17th, 2013, 09:52 AM

Hey guys
I needed a new engine for my Pregen Ninja an all i could find localy was a new-gen engine. after a lil reasearch i found out it was mostly straight forward match. Took a bit of work to get it in their but it all worked out fine.

I went to take it for a test ride yesterday an when i got back from a 7 mile round trip i noticed their was oil on the front of the engine. I then ran the bike in my garage an noticed a little bit of oil bubling out this pin sized hole under the exhaust ports on the head.

I looke don the pre-gen an their no suchj hole so im a bit at a loss. Can i just thread it an throw a bolt in there? is it drainning excess oil? any reason why only one of the two holes does this?

TIA

Joshorilla · November 17th, 2013, 10:03 AM

Not a scooby doo! But I am interested to find out!

Alex · November 17th, 2013, 08:15 PM

Quote:

Originally Posted by AFazakerley

Took a bit of work to get it in their but it all worked out fine.

Nice.

Would you be able to share some of the things you've had to do to make it work?

tubarney · November 17th, 2013, 08:58 PM

Quote:

Originally Posted by AFazakerley

I looke don the pre-gen an their no suchj hole so im a bit at a loss. Can i just thread it an throw a bolt in there? is it drainning excess oil? any reason why only one of the two holes does this?

If the oil continues to come out of the hole it means you have leaking spark plug rubbers. They are underneath the valve cover.

I'll get a photo.

tubarney · November 17th, 2013, 09:02 PM

There is 1 of these for each spark plug. You can replace them without having to remove valve cover, just unbolt it and pop it up a little, no need to pull everything apart. Get a Magnet on stick (there metal on inside).

AFazakerley · November 17th, 2013, 09:30 PM

Quote:

Originally Posted by Alex

Nice.

Would you be able to share some of the things you've had to do to make it work?

Yah, as far as fitting the engine into the frame everything was straight forward, except for the front mount. The male bracket on the newgen engine is about a cm (give or take) wider then the ones on pre-gen. To fix that i removed some material on the female bracket. The exhaust was slightly tricky, the pregen an newgen is completly diffrent. I used the pregen pipes/couplers system, just had to enlarge the holes on aluminum piece. Also removed the small studs an exchanged for some longuer ones. I plan on instaling the new-gen pipes once i order some because this system doesnt seal well
.
Electrical connectors were all the same, pregen carb with 1mm shims works quite well (not perfect), coilpacks and wires worked aswell. Prob more im forgetting.

One thing i havent figured out yet is the newgen has a breather hole on the top on the valve cover an makes quite a bit of noise. I put a small cone filte ron it for now.

Quote:

Originally Posted by tubarney

If the oil continues to come out of the hole it means you have leaking spark plug rubbers. They are underneath the valve cover.

I'll get a photo.

Quote:

Originally Posted by tubarney

There is 1 of these for each spark plug. You can replace them without having to remove valve cover, just unbolt it and pop it up a little, no need to pull everything apart. Get a Magnet on stick (there metal on inside).

The coolant lines hooked up easily aswell HOWEVER i had to remove the newgen upper hose connector on the top of the head since it has a 30degree bend compared to pregen thats straight. Thats when i had to unbolt the valve cover and must have shifted the gasket!

alex.s · November 18th, 2013, 04:30 PM

yeah as said above the spark plug gasket is leaking oil from under the valve cover into the spark plug wells. take the valve cover off , fix the screwed up gasket (probably replace as when you do that it bends the little metal part in the middle and it just doesn't work quite right after) and put it back.

MAKE SURE YOU DONT DROP THE LITTLE RUBBER THING DOWN THE WATER OUTLET HOLE!!!

MetaOrbit · June 5th, 2016, 11:35 AM

Sorry to bring this thread back from the dead (and slightly OT at that), but the photos in the original post are the closest thing I could find to an answer to my question... which is..

What is that tube/hose on the front of the engine? (Below the red circles in the first photo)

I seem to have some oil weeping from the fitting on the right end of the hose. I figured I can replace that hose, but having trouble figuring out how it's identified. My guess is this:

51044-0050
Tube-Assy, Crankcase-Head
http://www.kawasakipartshouse.com/oe...75b9/crankcase

Is that correct?

Thanks!

InvisiBill · June 5th, 2016, 12:03 PM

You have a typo in your part number, but yes, that's the tube in the first pic.

That one's not too bad, but Kawasaki's diagrams are higher resolution than a lot of the parts places' and they're usually clickable too. https://www.kawasaki.com/Parts/Parts.../2009/EX250J9F

MetaOrbit · June 5th, 2016, 12:11 PM

Quote:

Originally Posted by InvisiBill

You have a typo in your part number, but yes, that's the tube in the first pic.

That one's not too bad, but Kawasaki's diagrams are higher resolution than a lot of the parts places' and they're usually clickable too. https://www.kawasaki.com/Parts/Parts.../2009/EX250J9F

Awesome - thank you!

I didn't seem to find where anyone had detailed replacing this hose - should I simply assume it's as straightforward as it looks, or is there anything I should be aware of when swapping it out?

RacinNinja · June 5th, 2016, 12:36 PM

Quote:

Originally Posted by MetaOrbit

Awesome - thank you!

I didn't seem to find where anyone had detailed replacing this hose - should I simply assume it's as straightforward as it looks, or is there anything I should be aware of when swapping it out?

There are copper washers above and below the banjo fitting on both ends of the hose, IIRC.

Replace those and torque to manufacturers spec. Should be 4 washers.

Motofool · June 5th, 2016, 02:03 PM

Quote:

Originally Posted by MetaOrbit

.......What is that tube/hose on the front of the engine? (Below the red circles in the first photo)

I seem to have some oil weeping from the fitting on the right end of the hose. I figured I can replace that hose......

That hose is the Kawasaki's solution to carry pressurized oil into the head's mechanisms.

You may not need to replace the hose, just new washers and proper torque.

Picture is not of your engine, but it gives you the idea (part 15 without 14):

November 17th, 2013, 09:52 AM	#1
AFazakerley ninjette.org member Name: Alex Location: Woburnn Ma Join Date: Aug 2012 Motorcycle(s): 2000 Ninja 250 Posts: 71	New-gen engine in Pre-gen frame. Oil leak under exhaust ports. Hey guys I needed a new engine for my Pregen Ninja an all i could find localy was a new-gen engine. after a lil reasearch i found out it was mostly straight forward match. Took a bit of work to get it in their but it all worked out fine. I went to take it for a test ride yesterday an when i got back from a 7 mile round trip i noticed their was oil on the front of the engine. I then ran the bike in my garage an noticed a little bit of oil bubling out this pin sized hole under the exhaust ports on the head. I looke don the pre-gen an their no suchj hole so im a bit at a loss. Can i just thread it an throw a bolt in there? is it drainning excess oil? any reason why only one of the two holes does this? TIA

November 18th, 2013, 04:30 PM	#7
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	yeah as said above the spark plug gasket is leaking oil from under the valve cover into the spark plug wells. take the valve cover off , fix the screwed up gasket (probably replace as when you do that it bends the little metal part in the middle and it just doesn't work quite right after) and put it back. MAKE SURE YOU DONT DROP THE LITTLE RUBBER THING DOWN THE WATER OUTLET HOLE!!! __________________________________________________
	1 out of 1 members found this post helpful.

June 5th, 2016, 12:03 PM	#9
InvisiBill EX500 full of EX250 parts Name: Bill Location: Grand Rapids-ish, MI Join Date: Jul 2012 Motorcycle(s): '18 Ninja 400 • '09 Ninja 500R (selling) • '98 VFR800 (project) • '85 Vulcan VN700 (sold) Posts: A lot. Blog Entries: 1 MOTM - Aug '15	You have a typo in your part number, but yes, that's the tube in the first pic. That one's not too bad, but Kawasaki's diagrams are higher resolution than a lot of the parts places' and they're usually clickable too. https://www.kawasaki.com/Parts/Parts.../2009/EX250J9F __________________________________________________ * Unregistered, I'm not your mom and I'm not paying for your parts, so do whatever you want with your own bike. *

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MetaOrbit ninjette.org newbie Name: John Location: Bay Area, CA Join Date: May 2015 Motorcycle(s): 2009 Ninja 250r Posts: 6	Sorry to bring this thread back from the dead (and slightly OT at that), but the photos in the original post are the closest thing I could find to an answer to my question... which is.. What is that tube/hose on the front of the engine? (Below the red circles in the first photo) I seem to have some oil weeping from the fitting on the right end of the hose. I figured I can replace that hose, but having trouble figuring out how it's identified. My guess is this: 51044-0050 Tube-Assy, Crankcase-Head http://www.kawasakipartshouse.com/oe...75b9/crankcase Is that correct? Thanks!