1993 KLF300C bayou gasket issue

[Byron Tuininga]

Hi everyone,

Just looking for some advice on a Bayou 300 that I am working on cleaning up and rebuilding. I bought the beast for 200 and am going to be into it for about 1200 all said and done. I decided after changing the oil three times in just around three hours of driving and having it come out completely black that something was up. That and the clutches were slipping. I believe now that the previous owners had not used the correct oil for the wet clutch system. Both were toasted and nearly metal on metal.

Anyway, when I started opening it up I realised there was a massive amount of sludge and gunk inside so I decided to crack open the crank case as well to clean it all up nice while I had the motor out. 

This is my question now, I cannot for the life of me find a gasket any where that is for between the two crankcase halves. Is that normal. There was gasket material that was between them originally that would not be reused. Can I just use a gasket maker like ultra black or something of the sorts or am I best off to get gasket material and painstakingly cut out all the shapes and lines and get a gasket made that way?

Or does someone know where I could get a gasket?

Thanks in advance everyone.

Byron

Edited November 18, 2018 by Byron Tuininga

[wanrep]

It's not uncommon for case halves to not have a gasket.  Your Bayou is one of them.

I use Threebond 1184.  Just a light coat on one case half then assemble.  Make sure both surfaces are cleaned with brake clean before applying.

Each manufacturer has their own case sealer also.  Yamabond 4 is a good one.  Suzuki, Honda & Kaw have theirs too.

I'd stay away from silicone sealer although it can be used in a pinch. The mistake guys make is using too much.  It gets into oil passages and blocks them.

[Byron Tuininga]

Thank you for the info wanrep. I ended up looking through the service manual and finding that it said to use liquid gasket. I guess I should read the instructions first... :)

I will look up that Threebond and give it a go. I'll try and post some pictures too.