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April 26th, 2004, 02:51 AM   #1
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Oil leak - is this a new one?

Hi all

This site will be back up to speed in no time!

I noticed a small oil leak from my '03 650 the other day, it was running down the back of the engine in front of the swingarm pivot. On further investigation is looks as though the leak is from the shaft of the auto decomp mech that is activated by the kickstart (ie the bit next to the starter motor). Anybody had this before and, if so, is it a difficult one to fix??

Cheers

Jerry
PS at least now I don't have to feel guilty about not checking the archives first!!
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April 26th, 2004, 04:35 AM   #2
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It happens.

Some have slipped a little o-ring on the shaft when they've had the kick start mechanism out.

I have resolved this before by just greasing the shaft.

HTH
Simon
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April 28th, 2004, 02:24 PM   #3
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oil leak

Hi,

almost every Berg has this oil leak at the decompression shaft....live with it!!!!!!......there is no fix for good!!!!!
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April 29th, 2004, 02:53 AM   #4
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Not true, this is a design flaw.

Spot face the crank case and fit an o-ring (means clutch removal, etc). - this is a known fix. Problem is more of an issue with the 650 than smaller bikes due to greater crank case pressure.

My 2003 650 leaked oil from the oil filter cover, water pump, rocker cover and decomp lever at the crank case - this is unnaceptable for a bike that costs so much and supposedly hand made (which to me means attention to detail)!

For info, the 03's that got to Australia had 02 engines (easy check is to see how many oil drain plugs there are on the RHS crank case - 02 has 1, 03 2).

I returned the bike to the dealer and wouldn't accept it until fixed - I new more about the bike than they did! Ended up dealing with Husaberg Australia direct - took 6 weeks to get a result (bike was still under 1 year warranty).
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May 2nd, 2004, 07:09 PM   #5
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jerryt, the decomp shaft doesn't have a seal on it, just a brass bush.

Here's how I fixed mine.

1) Remove the battery holder.
2) Remove the decomp cable.
3) Take an oring (8mm ID, 1mm thick) stretch it onto the decomp lever.
4) Refit the decomp cable.
5) Have a mate run the kick start to the bottom of its stroke.
6) Now ask your mate to slowly allow the kick starter to return to the top.
7) While the kick start is returning, the decomp shaft will slide out of the casing about 10mm. Hold the kick start in this position.
8.) Slide the oring down the lever and onto the decomp shaft.
9) Refit the Battery holder.

I did this fix 18 months ago and it still doesn't leak.

It is important that you do not use an oring thicker than 1mm.

Don't operate the kick start while the decomp cable is removed.

When I first got my bike it leaked badly, I couldn't believe it when the dealer told me they couldn't do anything about it as there was no seal so I sent an email of to Husaberg in Sweden. The oring was their suggestion.
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