Oil leak with bike on Abba stand

[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?