Oil Leak - Clutch cover 1st Gen SV650

[twowheels]

Hello.


Right i took the clutch cover off my race bike to measure up the clutch plates, they are fine - which was nice.

when i put the cover back on with a clean o-ring with a film of oil as suggested in the manual, the bike began to leak oil from the cover. - i refitted it with a healthy does of hylomar!! this fixed it for 24 hours, the leak has come back but very slightly.

Now i have read about his and there are ideas floating around that its a defect of the part....it warps.........has anybody here found a fix for this and actually seen it work?

Im thinking of swapping it out for a pointy cover although due to the oil level windows not being the same place im not keen on the idea

the other option is to replace just the inspection cover too

any ideas? its driving me MAAAAAD!!!

Thanks

[AndyBrad]

Replace the o-ring with bigger section chord and fit real bolts.

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[twowheels]

OK cheers bud! do you think 3mm cord will be too big?

[garynortheast]

I replaced the original crap plastic cover on mine with an alloy Woodcraft version. Doesn't leak and looks much better.

[AndyBrad]

Yes but a new cover is £££

It will be 3.1mm chord probably. Will work fine but the cover won't sit flush with the casing due to the size. Just tighten it enough to squash the o-ring a little.

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[twowheels]

yeah man i hear that, i cant be shelling out hundreds on a new cover with all these tyres i need to buy for this season!

ive found a new plastic cover for 60 quid - i might run with that if the chord dont work but thats the cheapest option so ill be trying that first!! cheers all

[martin15s]

Clean and dry the old o-ring, then cut out a very small section and superglue the ends. You can also use a good quality crankcase sealant. have tried both successfully.

[rictus01]

it's also important to tighten the bolts correctly (as in opposite each other pattern) as this will warp the cover if not done right.

cheers Mark

[twowheels]

Cheers Martin i think i will chop some of the o-ring out and use crank sealant this time round!

if that doesnt work ill order up some oring cord and make a new o-ring up! wow a whole extra little project, im so lucky after having to helicoil my cam journals last month!!!

[Geodude]

Mine constantly dripped (warped cover) so i fitted a new 'standard' ring gasket and used this halfrauds 5910 (http://www.halfords.com/webapp/wcs/stores/servlet/product_storeId_10001_catalogId_10151_productId_17 3106_langId_-1_categoryId_255217) stuff and its been good since HTH


+1 on what Rictus said

[saintnick]

think I posted up about this recently in the clutch random disengage thread.

the oe plastic cover is often fractionally out of true alignment, plus the black paint finish on the clutch side is uneven, both of which = potential for oil seeping when warm.

cheap answer is black gasket sealant used very sparingly, job done.

[twowheels]

that bits covered i always use the correct torque wrench on engines cheers lads

[twowheels]

OK ive tried cutting the seal down and using sealant and it is but almost gone however i feel the minute i give it good spin no the track itll turn in to a stream!

So i have taken to the decision to replace the casing with a point casing - does anybody know how far off the oil window is??

[saintnick]

to save money time and weight

1) make sure that thin little gasket/o ring is sound

2) scrape off any black paint on the bottom half of the clutch basket housing, this ensures an even surface around the seal in the most vulnerable place

3) use a quality instant gasket sealant. Sparingly.

Do that and it wont leak at high temp - not making it up, tried and tested ;)

I know of another one where the owner just used sealant. No more problem. btw my bike and his were both first gen like yours/