Oil leak with bike on Abba stand

[fchat63]

Hi all,
Anybody had this one before.
Had the bike, 1999 curvy , on an abba stand to get the wheels off for new tyres so had to weigh the back down to get the front wheel out which meant the front of the bike was a bit higher than the back. After a week a small oil leak appeared which looked like it was from the right side of the engine as you sit on the bike. Put the wheels back on, bike back on the ground and propped the back on a paddock stand and the leak seems to have gone. I’ve never noticed any oil drips under the bike since I’ve had it and when I check the oil level it doesn’t need topping up.
Any ideas?

[gibbzy2k1]

Would it be the usual Clutch cover leak? mine has a leak, but when checking the level it doesn't need topping up so it can't be that bad?

[andrewsmith]

Clutch cover is warped.
Being serious, pull it off and see how warped it is, if it over 2mm across its not worth grinding down.

The bad news is a new one is around 90 quid plus the gasket and shipping from Fowlers. I know as I knacked the clutch with a naff lifter and warped cover

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[maviczap]

Pointy ones will also fit, so don't limit your choice to curvies.

[gibbzy2k1]

Plenty of pointy ones available. i am thinking of doing the swap, means a coolant change too? So might changes the hoses for blue ones while I am at it.... The list begins...

[maviczap]

Plenty of pointy ones available. i am thinking of doing the swap, means a coolant change too? So might changes the hoses for blue ones while I am at it.... The list begins...

No coolant change required, and if you do it on the side stand, you won't loose any oil.

[gibbzy2k1]

No coolant change required, and if you do it on the side stand, you won't loose any oil.

oh cool. I though I would have to remove the water pump or something as the pointy cover is a once piece?

Even better.

[maviczap]

No, not to remove the clutch cover

http://forums.sv650.org/showthread.php?t=221330&page=2

[Bibio]

before you go ripping things apart its best to make sure that its actually leaking where you think it is. clean the seal area around the clutch cover then put some talc around the area you cleaned. put bike on abba stand then leave it till it starts leaking. if there is no damp parts to the talc then its somewhere else.

[fchat63]

Thanks for the advice guys but why would it leak on the Abba stand and stop when it's back on the ground? I had it on the stand for a couple of months in my front room while I changed the handle bar set up and no drips or does it stress the engine lifting the front up?

[gibbzy2k1]

Could it be the change of oil level and depending which part has warped could it be the leak as not at the bottom but towards the back slightly higher up?

Only a thought. I think mime is leaking from higher up on the cover, only really shows when the bike has had a. "good" run.

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[yorkie_chris]

Sod it, if it's only a small leak leave it alone.
Don't fit the far inferior pointy cover either. For a start the oil window is in a different place which you'll need to account for.

Maybe a woodcraft one if you're feeling flush :)

[Fen Tiger]

If you can't see where the small leak is coming from and as it was only noticed with a change of attitude when the bike was on the stand I would be inclined to let it develop until I knew what was going on. Sounds very slight and maybe just oil which has pooled and then spilled with the bike being tipped up. Could it have come from around the front sprocket fling or pooled WD40 or other spray on the crankcase. As Bilbio has described, make sure you know where the leak is before dismantling anything.

[fchat63]

Well, cleaned it all over and it would appear that it's the clutch cover. Not a big leak but more a weeping. Going to see how it goes, we've got a small run to Exeter on good Friday which should show up any problems.
Silly question I suppose, but Has anybody tried making a gasket?

[Adam Ef]

I've used gasket sealant (Loctite 5922), but with a gasket too. Some people use it on it's own.

[yorkie_chris]

Well, cleaned it all over and it would appear that it's the clutch cover. Not a big leak but more a weeping. Going to see how it goes, we've got a small run to Exeter on good Friday which should show up any problems.
Silly question I suppose, but Has anybody tried making a gasket?

There's an O ring under there. Don't think a gasket would work.

[Red Herring]

Have you checked all the bolts are actually tight?

[fchat63]

Yep, all the bolts are tight. I did have a belly pan which used one of the bolts to hold a bracket and one of the mechanics from a local Suzuki dealer thinks that may have contributed to warping the cover.
Going to see how it looks after this weekend and then check it for distortion, a new O ring and sealant.


Thanks to all for the feedback.

[Dipper]

Mine was leaking when I bought the bike, I removed the cover, removed all the gasket sealant someone had put on it in the past, cleaned all surfaces and the o ring, put everything back together and most importantly torqued it up to the specified setting. That was 5 years ago and all has been bone dry since.

[fchat63]

Well, got the new O ring, cleaned up the cover and whenfitting noticed a small amount of coolant leaking from the top bolt hole!
Is that normal, the bike had been on its side stand for aweek and I had to top up the coolant to the correct level. Bolted the coverback on with just the O ring and a smear of grease, torqued up to 10nm and I reckonthat’s cured the oil leak but there does appear to be a very small coolant leakfor said bolt hole, not dripping but a definite wet spot at the top of theclutch cover.
Anybody got any ideas or had this problem before?

[fchat63]

So finally got to the point where I think I need a newclutch cover. Can’t stop the leak and tried everything I can think of.


Can one of you guys suggest the best place to get a clutchcover for a 1999 model? Reckon it’s going to be a non-original part or is itworth trying an original part from someone breaking a bike?

[Bibio]

which part is leaking, the outer round cover or the main casing?

[andrewsmith]

What Bibio said

If you need to replace it (it's got to be properly warped) new oem parts are available from fowlers

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[andy650]

If its the round centre leaking, it should be fixable?

I did mine by sanding flat on a sheet of MDF, and shortening the spacers, also by sanding. Didn't replace the oring.

Been leak free for a few years now.....

[fchat63]

It's the round cover that has the rubber o ring.
Maybe I'll give sanding it another go before I buy one.
What's the best way to check it for warping?

[Bibio]

place the cover on a flat surface and try to stick the thinnest feeler gauge you have at points round the cover. if the gap is more than 1mm then its fubar.

you can "lap" the cover by using a thick sheet of glass and grinding paste till the gap has gone. use a figure of 8 while grinding it and also rotate the cover every so often.

when installing the cover back on you must torque the bolts in a star configuration (opposing bolts) or you will warp the cover again.

all mating surfaces must be completely dry and clean without scores DO NOT USE A SCRAPER.

put all the bolts in
finger tight all bolts using star
half torque bots using star
final torque using star

if you still cant get it to seal then use a smear of JB Weld as a gasket sealer and let dry overnight.

[andy650]

I lapped mine with fine sandpaper, taped on MDF, far quicker than paste, and sealed properly afterwards with the old oring!

You must shorten the spacers though, otherwise they are too long and dont allow the cover to the nipped tight on the oring. I took about 1mm off them IIRC.

[fchat63]

Thanks Bibio,
I'll give that a go and post how I get on.

[Bibio]

good point andy made in shortening the spacers. though personally i dont like the taped down wet'n'dry, its not flat enough.

[fchat63]

So, do I push out the spacers and lap down the case then grind down the spacers so when they're back in they're level with the case. Then that should nip up the o ring when refitting?

[Bibio]

come to think of it are there any spacer/pegs on the outer clutch cover?

[andy650]

Not sure about the outer cover Bibio, never had it off.

Yes Fchat, push spacers out before you lap the cover. I made mine a tad shorter than the lapped thickness of the cover, because the heads of the bolts will embed themselves into the cover over time. This is why it warps and leaks in the first place, but I suspect/hope it will be less likely now as the plastic under the bolts will already be a little compressed.