Lots of smoke, oil dripping on ground

[Mikeyx]

^Choke is in the carb.

[Mikeyx]

Okay... there was coolant in the crank case. Got some 100 ml or so from the drain. Apparently 'smoke' was coolant after all.

I guess there are several possibilities here?

- cylinder bottom gasket
- cylinder head o-rings
- engine case gasket(s)

[Zman]

Check all three of those. Use a straight edge and look for flat surfaces. Over-tighening and or over-heating can cause warpage and poor gasket problems.

[Mikeyx]

The cyl bottom gasket was soaked with coolant, making the gasket swollen and softened (non OEM part).

There was one crack as well, but it may have occurred when removing the cylinder.

Rear nuts had been tightened with a torque wrench. Upon disassembly, the front nuts were much easier to loosen.

[Jacob 'Berg]

Originally Posted by Mikeyx

The cyl bottom gasket was soaked with coolant, making the gasket swollen and softened (non OEM part).

There was one crack as well, but it may have occurred when removing the cylinder.

Rear nuts had been tightened with a torque wrench. Upon disassembly, the front nuts were much easier to loosen.

Sounds like you will need to split the cases. Check the case halves where the coolant passage is in front of the crank case. It is likely you are leaking coolant into the crank case where this passage is. Use a quality gasket and I would add a small amount of Yamabond around this passage.

I had a similar issue after reassembly of the case halves on my 2011.

[Jacob 'Berg]

Sorry, just noticed you mentioned the leak appears to be at the base gasket for the cylinder. Hopefully a new base gasket will be the fix.

[Mikeyx]

I received a new gasket from motocrosscenter.com. It is made of completely different material compared with the failed one (sourced from gasgas-outlet.de). The previous gasket was kind of 'paper'...

[Mikeyx]

I did not find any source for the 'oil' dripping down. I guess it -most likely- originated from the grease applied on the swing bolt?

Sold the bike yesterday, and now I'm a happy owner of a 2018 Husky TE300i.

OMG how much technology has developed (electric starter, TPI, BALANCING SHAFT). A completely different riding experience!

[cbutler]

Congratulations on the new KTM