Hi. I was on these forums some time back for a electric charging issue. While replacing the stator (unnecessarily), I decided to install a new gasket. I was everything was fine. But I noticed it's leaking oil now. Previously, there was no leak, so this is attributable to replacing the gasket. I can see it collecting at the lowest bolt on the stator case (left side).

Funny thing is I've seen the drips coming from around south of the oil filter area. I can't 100% see where it's originating from, but after riding and coming back to the back, I will see oil drips under there. The riding could cause the oil to move around, so I don't really know the origins of the leak.

Did I mess something up? Maybe overtightened the bolts and caused a fracture somewhere? Maybe I did not shave my old gasket off enough (I used a razor and did my best). My bolts should be 100% fine. I have an idea to use permatex gasket glue to just cover the entire bottom area of the stator case to rule that out as the origin of the leak. Does that sound like a good idea? Or maybe just buy an entirely new stator case?

Its a possibility you didnt remove all of the old gasket. also a possibility that the razor nicked the case or mating surface. (its aluminum it IS possible) also possible bolts werent torqued to spec. you saying it only leaks after a ride?
Aaron

It's very possible that I needed to shave more of the gasket off. But it was RIDICULOUS! I drenched it in hot water, I shaved and shaved... I honestly feel it would be smarter to just buy a new case if anyone does the same. Or better yet, just reused the existing gasket if possible.

It definitely seems like it only leaks after a ride. I'll not ride for a few days, not see any fresh oil spots. Then I go riding, come home and see visible oil spots. That's purely observation though, I can't really know for sure the leak pattern.

I had a very similar problem very recently. When the oil is coming out from those gasket areas, it gets everywhere and I mean everywhere. Especially if you ride in a spirited manner as I often tend do. It was my gasket and I had oil all over my engine, visually looking for the oil problem was a nightmare. I later found out my clutch cover gasket had a huge tear in it when I saw oil gushing out the top like a geyser.

You're only seeing it after a ride because the oil pressure rises when you're going and it gets forced out of the weakly sealed areas of your gasket, then the wind pushes it all over tarnation and you can't pinpoint the leak...

To get those baked on old gaskets off, you basically have to buy aerosol "gasket remover". I could only find it online. All the brick and mortar stores around me didn't carry it.

What I'd do is play it safe. Remove that cover and gasket, spray liberally with gasket remover (cover your paint, it will strip it in a moment) let it sit about 10-15min and scrap it off. Do that until the surface is clean. When you can run your finger along the mating surface and you cannot perceive any bumps or inconsistencies I'd say that's "good enough". Be careful with hard things like razors, like yamahonkawazuki Aluminum is very soft and will be nicked very easily. I used a razor, just try to keep the blade perpendicular to the surface and scrap small areas, take your time and don't get crazy with the scraping. Cleaning baked gaskets off aluminum is one thing in life that tests your patience. You can also try a plastic scraper, but those never worked well for me.

Also, scrap the other mating surface that is on your bike... I forgot until the last second. Shouldn't be as bad as the one the gasket is stuck to, though.

BTW, be careful if you do use that gasket remover, it is vicious stuff. It will burn your skin on contact and it does not feel good (ask me how I know). I'd suggest safety glasses and some Butyl rubber gloves. Outside is preferable.

Try that and see if the leak persists. I had 5 potential leak points on my bike and turns out it was just one place. Worth a shot.

Paint stripper carefully applied with a cotton bud is just as effective and far more user friendly than aerosol gasket remover 

thanks for the tips. i guess i feel a little better knowing i'm not the only one with 99 problems and a gasket is one of them? i think i spent about 1 - 1.5 hours scraping the old one before I just said "ahh... good enough'.