Leaking clutch casing

Hi people,
Can anyone help. After replacing my clutch casing o ring on my 2000 curvy It's still leaking and worse than the old one was...why?
Is there anything I can do or anything I haven't done to stop this? Someone said I might have over tightened it..If so, is the o ring knackered?

[maviczap]

Its a notorious problem and possibly caused by a warped clutch cover, as its only plastic.

Do a search on the Org for solutions, but a replacement cover might be the answer.

Either that or take the cover off and see if the O ring is seated properly

Thanks for that. I did do a search and it seems to be problem right enough!
one post said to take out the bushes in the casing and reseat it with the o ring and gasket sealant and tighten down with washers instead.
Does this sound like a plan or would it bad!!

[maviczap]

Pass, as my clutch cover doesn't leak at the Mo. Touch wood

New ones aren't that expensive, I think

Get the part number from here

http://www.alpha-sports.com/suzuki_parts.htm

Then see what the price is by copying the part number into the search engine

http://www.robinsonsfoundry.co.uk/offline.html

Site is down at the mo!!!!!!!

A new one won't have warped, but it will pay to tighten any cover evenly

Hi there,
As Mavi has said
you may have over tightened them unevenly causing casing distortion or even pinched the seal between the two mating surfaces. Best to start all over again, ensure ring is without imperfections, fit into recess with a smear of grease (will help keep in place) then offer up cover carefully to not disturb seal. Put in the screws, once casing located, holding casing gently in place. Do up the screws finger tight in a opposite and diametrically tightened order rather than round the clock wise. ie tighten 6 oclock, twelve oclock, three oclock, nine oclock, one oclock, seven oclock etc Then tighten all in the same fashion evenly to manual torque or just nipped up finger tight all round. Put in the oil and see if any leaks when engine warmed up and running - often at the bottom - then see if you can trace location of leak. If there is one you might try slightly tightening the local surrounding screws a tad - it may stop.
Good luck and hope this helps!

Thanks for all the advice guys..I'm on the case.
Cheers,
Douglas

Just a quick update.
I ended up taking out the bushes from the casing and using gasket sealant and washers, as nothing else would work.
That seems to have cured it..600 miles and no leaks!
Thanks again for all the advice.
Douglas.

Well done Doug, nice one. Always good to get oil leaks sorted and back on the road - keep an eye on it though. Have always been amazed with our Raced SV how many things need checking and double checking, the bits that can work their way loose just when you dont need it. Touch wood this year nothing has fallen off! Apart from the rider that is...............

[TSM]

the bushes are there to prevent when overtighting of the bolts causing the plastic to split
its likley this will only work for a small ammount of time, the general considered fix is to use silicone sealant or gasket sealant over the original seal before you put it on the bike