Re: Oil leak!
 

It looks like it's the home of the oil jet (for the transmission). The manual doesn't show it very clearly (and it's a black engine). The picture was taken from Section 3-73 of the curvy manual So, if it is the home of the jet, oil would be under pressure there. The second pic describes the lower bolt where your casing is damaged as an oil gallery bolt - so an internal oil transfer pathway.

Re: Oil leak!
 

Looks like the oil galleries are cast into the engine (which coming to think of it is why they are called galleries and not pipes), which is where the 'oil gallery bolts' comes in, they are probably there just as an access point to clear out the gallery after casting and then used to seal the access holes.

If the black bolt will not come out to enable gallery hole to be blocked with welding, I would be tempted to make a repair with it in-situ using plastic metal, (it is amazing stuff and it can even be tapped with a thread after it has cured). the area would need to be degreased thoroughly (brake cleaner spray or similar).

Anyone done this before ? I have used plastic metal to make repairs to aluminium castings before, but never on an engine.

Re: Oil leak!
 

After thoroughly cleaning around the gallery bolt (which sheared off inside) I've applied metalset, and will later be applying another layer of prc to give it the best chance at holding. Will keep updated after refilling with oil and running, if this doesn't sort it then it's back to the drawing board.
https://uploads.tapatalk-cdn.com/201...75f39afb9a.jpg
https://uploads.tapatalk-cdn.com/201...0fb10d9532.jpg


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Re: Oil leak!
 

As my Dad will say 'It's got two chances'

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Re: Oil leak!
 

best of luck


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Re: Oil leak!
 

well, there's always these...

http://www.ebay.co.uk/itm/suzuki-sv-...0AAOSwKOJYGemx

Re: Oil leak!
 

The extreme solution! Could the sheared off bolt remains be extracted to enable a new one to be put in?

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Re: Oil leak!
 

I'm already watching those on eBay haha, the seller hasn't responded to my messages though! If this current method doesn't hold then I'll be trying to extract that bolt, but against a cracked casing I think it's more ideal to plug it completely.


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Re: Oil leak!
 

If the metal bond doesn't hold you have a Boyes supermarket not far.They do a great water based epoxy putty.I've used on Motorcycle radiators to repair tubes and loads of other jobs.It's called,"Milliput" is a two pack mix

http://www.ebay.co.uk/sch/i.html?_fr...liput&_sacat=0

Totally clean the area to be sealed.Mix putty and use some spit on the putty and work it.This creates a kind of,"Potter's slip" glue.Press onto job.
Once it sets it is oil and waterproof.

HTH :)

Re: Oil leak!
 

ooohhh dear me. the top of that bolt has an oil jet there, if its missing then good luck. even worse if someone has stuck too long a bolt in and blocked the gallery.