Curvy clutch cover oil leak.

[Goodfella]

Oil seems to be very slowly leaking from these two bolts on the right side, the lower one is tight but won't actually fully tighten just keeps going round, the upper bolt seems to be ok, but still leaking.

Would I be right in assuming I need a new gasket?

http://i6.photobucket.com/albums/y217/Applecorp/bike.jpg?t=1345728165

[Destruktor77]

I'd say new gasket.

It might be worth checking the thread on the bolt and the in the cover to make it aint cheesed.

[Goodfella]

Ok thanks matey, will have a look now.

[Goodfella]

Just had a look, bolt seems fine but as I said it gets to a point where it's pretty tight but it just keeps going round, unlike the other bolts.

[jambo]

My first guess would be:
1) The clutch cover is plastic, and these have been known to warp
2) A little oil has started leaking out
3) Someone has tried to tighten up that nut to stop the leak and has stripped the thread.

This would not be the first time this has happened, and may mean that the easiest fix is to get a replacement RHS case cover, and swap all the components over. Pointy engines have the clutch cover as part of the case cover all as one piece to stop the leak, but then to get to the clutch you need to drain the coolant system because you'll be undoing the water pump...

Jambo

[NTECUK]

Try a helicoil as the threads goosed

[phatwheels]

it'll be an o-ring you'll need, not gasket. cost you £12 n'all!

im experiencing the same problem as we speak, from the same bolt, on the same side of bike.
ordered new o-ring for the clutch cover outer, replaced it, and still got a leak. reluctant to tighten much more.

got bike propped over on its side against garden wall right now, wondering whether to take the cover off and add a litte ring of Instant Gasket, as well as leaving the o-ring in place, anyone know if this is a good/bad idea?

[NTECUK]

Check the cover is flat. A pain of glass will do if you can't find anything more suitable.

[garynortheast]

http://forums.sv650.org/showthread.php?t=182662&page=2

[dizzyblonde]

My first guess would be:
1) The clutch cover is plastic, and these have been known to warp
2) A little oil has started leaking out
3) Someone has tried to tighten up that nut to stop the leak and has stripped the thread.

This would not be the first time this has happened, and may mean that the easiest fix is to get a replacement RHS case cover, and swap all the components over. Pointy engines have the clutch cover as part of the case cover all as one piece to stop the leak, but then to get to the clutch you need to drain the coolant system because you'll be undoing the water pump...

Jambo
This.
It's a common.fault with an SV of the older variety. Both of mine have done it. It also happens on the TL1000

[hardhat_harry]

Check that case is not warped, this can be fixed with a sanding table.
Check the plastic pegs that the screws sit in havent been pulled through (check they are same length).
If all else fails use threebond, its magic!!

[Thunderace]

If it's a very slow leak, you can buy redex oil leak stop, £4.50 from wilkinsons, just add it to your oil when warm, then run the engine for 10 mins or so, and it should stop any weeping from gaskets.

[phatwheels]

threebond, just been on the site for a look around, guessin itd be 'liquid silicone gasket' we'd need.

you know where to buy it in-store?
or will it have to be ordered online

[jambo]

If it's a very slow leak, you can buy redex oil leak stop, £4.50 from wilkinsons, just add it to your oil when warm, then run the engine for 10 mins or so, and it should stop any weeping from gaskets.

We know exactly where the leak is coming from, and can easily remove the component and inspect the gasket (if the bike's on the side stand you don't even need to drain the oil).

Adding something to the oil that can end up blocking oil pathways (admittedly this is unlikely) and affects every part in contact with the oil would not be my first stop. Though I admit this stuff has its place.

Jambo

[hardhat_harry]

Threebond is the same as Yamabond so local Yamaha dealer or if your not in a rush eBay always look to be the cheapest

[Thunderace]

Adding something to the oil that can end up blocking oil pathways (admittedly this is unlikely) and affects every part in contact with the oil would not be my first stop. Though I admit this stuff has its place.

Fixing a problem correctly is always the way to go, but to alleviate any concerns the redex stuff is just gasket conditioner, and being the bodge happy cowboy that I am I can vouch for the effectiveness, it works and has never done anything but stop leaks in any of the vehicles I've used it in.

Although it does make you a little concerned as it says on the bottle add when oil is full and it's a 400ml bottle, but as I say, never had any dramas with it, its just a cheap, quick permanent fix.;)

[Goodfella]

We know exactly where the leak is coming from, and can easily remove the component and inspect the gasket (if the bike's on the side stand you don't even need to drain the oil).

Jambo
What exactly do I have to do to inspect the gasket, what am I unbolting - all the greenish coloured ones? there are loads of bolts in that area. Will oil spill out at all?

Sorry, bit of a novice I'm afraid.

[Goodfella]

Also, it appears one of the bolts was over tightened or glued in place or something by previous owner, (I've only had this bike 3 weeks). I went to undo it it which took a lot of force and it's sheared off and snapped leaving half the bolt stuck inside. *sigh*

Now I have no clue what to do, how can I get this bolt out, where can I get a replacement?

Sorry for all the questions.

[phatwheels]

so you don't have to drain the oil you'll want the bike on its side-stand - or if you want to be extra safe, and have crash bungs, you can rest the bikes left side against a garden wall if its right height.

•leave it for 10-15 mins so oil runs to other side of bike, away from the cover.
•you want to take the outer clutch cover off, that means removing the eight bolts on the cover, including the one you circled on your picture - make note of what bolts come out each hole, there's 3 longer bolts for the top.
•cover will come off now, check the o-ring, mine looked ok but i replaced it anyway with a new one (£12 for what was essentially an elastic band!!?)
•check the cover isn't warped by placing it on a flat surface

if your cover aint warped stick your new o-ring in and bolt it back up, fingers crossed its no longer leakin.

If the covers warped, some ppl say you can level it out again using a flat surface and some sandpaper, rub the cover on the flat surface until no longer warped. - i aint tried this, so cant say how well it works. other options are order new OEM plastic cover, or order an aftermarket steel cover (which won't flippin' warp) but a lot more expensive.

BUT you've now got a snapped bolt too, wahoo. - only thing i know which might sort this is to drill it out, and use a helicoil? someone else may have to confirm this tho - never messed around to this extent, but either way, i think its a job for the local garage now!

not sure where to get a replacement bolt, maybe try a scrappers, if they got any sv's in.

[Goodfella]

Appreciate the reply phat very informative, but yeah, it now looks like a trip to the local garage.

[phatwheels]

just incase it is your cover, ive just come across this while lookin for a tank bag believe it or not haha...

http://www.ebay.co.uk/itm/suzuki-sv650-clutch-case-engine-cover-1999-2002-/261085305038?pt=UK_Motorcycle_Parts&hash=item3cc9e598ce#ht_500wt_899

[phatwheels]

might even end up in a bidding war with you over it if my plan to seal my leak with instant gasket fails!