KPX 250 Gear Indicator Oil Seepage
 

For the past few thousand miles, I've had some oil seepage from around the gear indicator module on my KPX 250. A hundred miles or so ago I drained the oil, pulled out the gear indicator module and replaced the rubber O ring with one of a slightly larger diameter. It definitely fit tighter when I replaced and did not have anymore oil seepage again until this week. In the attached photo you can see a small amount of oil that is just below the gear indicator module. The leak hasn't been enough for me to have to add oil between changes but it is very annoying to have even a slight oil leak.

I don't know why this would keep happening since its not a wear part so I'm thinking to pull the module again and use some Permatex 82180 Ultra Black as a surface gasket. Has anyone else had this issue and does it sound like a good idea?

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Personally I prefer Hylomar as a sealant in situations like this

This really looks like minor mop up level seapage? If it gets worse, it might be worth more attention depending on how frequently you are changing oil. The important thing is- does this actually result in a significant cc drop in oil ? You can add a little oil periodically.

They'll sometimes be enough that I'll get a drop on the ground but not enough that I have to add oil between oil changes. It hasn't gotten worse over time, just an annoyance to have an oil leak on a new bike and that it could get worse over time. The O ring should be enough to prevent the leakage so I'm puzzled why its even happening. When I take the module off this week I'll look closer at it to make sure there are no cracks in the plastic then I'll try some of the Permatex, because that's what I have, and see if that resolves it.

Did you check for cracks or imperfections in the module itself?

I'm going to take a closer look at it when I take if off this week. A crack would at least provide an explanation.

I haven't used Hylomar. I see various products and packaging. Gasoline/oil resistant. There are definitely Permatex solutions too.

The gear position sender has that wiring passthrough. The leak may follow the wires, or at the base of the module. I would clean it up and apply it on the inside wire connects, wait a day, then apply it to the sealing surface and install it.

This wiring connection is a reasonable place to develop a minor leak. Yes, annoying but fixable.

Hylomar is great stuff. Non-curing sealant, and completely oil resistant. Great for sealing when the parts are 2 different materials and the sealant needs to be flexible. Also makes a pretty good method for retaining bolts.

Hylomar is available from a ton of different sources. I've been told (but I'm not a chemist who can actually confirm) that it's the same formulation as Hondabond, Yamabond etc.
I've used it to seal up cracked intake boots, added to old (unavailable) carb bowl seals so I can reuse them etc.
Most recently I've used it to install the oil separator plate and oil pump on my Subaru engine rebuilt project, will also be using it when I reinstall the sump.
The petrochemical resistance (fuel and oil) is a huge advantage and since it doesn't completely cure there's no concern about chunks of it getting in the oil and clogging up a filter screen like a glob of traditional sealant can.