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Bottom Right Oil Leak Help (With Pictures)

Started by stokes776, October 22, 2015, 12:32:52 PM

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stokes776

I started troubleshooting a leak coming from the right side of the bike. Came out of work one day to find a little pool of oil under the bike.

Found that it was leaking through the top right of the Clutch/Crankcase cover gasket.
Ordered Gasket from Bikebandit. Drained Oil, Removed Crankcase cover, found that the gasket was a little damaged, didn't line up right, matched visible leak location of top right of the crankcase/clutch cover (if looking at the bike from the right side.

Installed new Gasket, Overtorqued and snapped a bolt, grabbed new bolt from old engine, got it all sealed back up with less torque.
Cleaned off all of the oil and filled it with new (15W-40 Rotella) started it up.

No visible leaks, took it for a 20 minute ride and immediately parked it over the cardboard in the pictures below.

Even before the kickstand was down, it started dripping oil again. Not from the top of the clutch/crankcase cover this time, but somewhere on the bottom I am thinking?
It is collecting onto the frame and dripping down.

And that is why I am posting. Does anyone have any experience or history with leaks from this side of the bike?

My current next steps.

1. Fire it up again, run it and get it leaking and watch it, try to find it visually.
2. Double check my torque on the cover bolts. I used the 8mm torque settings from Haynes manual. Snapped the bolt and had to remove everything.
When I put it back on the second time I did hand tight plus 1/4 with a socket. Reading online it looks like I am not the first to make this mistake, and that the bolts are actually 6mm or need that torque setting? Maybe going back over the bolts with my torque wrench for that setting will seal up the gasket if it is leaking from there still.

2. Maybe replace the Oil Crankshaft Seal? The rubber donut thing that stays on the Clutch/Crankcase cover when I removed the cover.
I just re-used the one that was in there. After the work it seems like there is some oil coming through that cover a bit, and getting the wire coming out of the cover, with that half moon rubber seal a little wet with oil.
I think item number 12 at the link below. If anyone could confirm!
http://www.bikebandit.com/oem-parts/2004-suzuki-gs500f/o/m6061#sch504181

3. Replace this oil Pressure port thing I think might be leaking, Item 9 and 10 here
Probably just need the gasket itself.
Ive never opened this port. I think its for measuring the oil pressure with an external tool.
It is wet with oil. Suspect maybe it is leaking?
http://www.bikebandit.com/oem-parts/2004-suzuki-gs500f/o/m6061#sch503046










sledge


fetor56

Clean thoroughly and find EXACTLY where the leak is.

Rallyfan

Clean it completely with simple green and water. Dry completely; I use compressed air or a leaf blower plus time. Then cover in talcum powder. The leak should be easier to spot, and the bike will have that barber shop fresh scent.

stokes776

So quick update.

Finally had some time to take a look at the bike.

Started by spraying some simple green and wiping off the area as suggested. Couldnt really get the bottom, where the Oil sump is, but tried the best I could.

Took a torque wrench and checked the cover bolts against 55 in/lb of torque, they all checked good. Took a 17mm I think to the Oil Pressure Plug bolt and gave that a few tugs. It might not have been 17mm because the socket kept slipping, but I dont have a standard set above 13mm and it was larger than that.

I then started the bike up and let it run in the garage for about 20 minutes while I watched it very closely. Not a drop of oil anywhere on that right side.

Strange, I was expecting something to come out. I didnt really even do anything except clean it and check the bolts really. Took it for a quick ride around the block, came back into the garage, checked again. Dry. Took it for a longer ride, 25 minutes. Checked at halfway point, dry. Checked again at home at end of the ride, dry.

Magically fixed. Maybe the new gasket just needed to get settled?

Rallyfan

Time will tell but I'd check closely and frequently.

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