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April 14th, 2015, 02:40 PM   #1
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My FS650 is leaking from clutch cover.

Hello folks!

I just bought my FS650 2006(or 2007) and after finally fixing a leaky weep hole, it started leaking oil from the back of the left engine case cover (aka clutch cover?)
The gasket was even brand new and everything
After inspecting the clutch cover, i found some small scratches where the gasket goes, They were so small that i would never think they would make it leak, but the leak is from that exact same spot

So my question is: Can a scratch this tiny really make a oil leak? If not, have i just screwed up my gasket upon mounting the cover?

Any feedback is taken with great gratefulness!


Last edited by SnickaSnick; April 15th, 2015 at 12:49 AM. Reason: Re-sized the image down a bit.
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April 14th, 2015, 03:25 PM   #2
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Resize that photo! Way too large.

As for the leak, if only small scratches, consider applying gasket maker along with the OEM gasket. The gasket makers available at auto stores claim to fill gaps, scratches and grooves up to ?? 0.05" ?? (I forget the value, but it will fill a normal scratch).

Be sure to use a razor blade or similar to remove any old debris from sealing surface. Sometimes an old gasket chunk can become stuck to the surface and cause havoc.
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April 14th, 2015, 03:27 PM   #3
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I'd check to see if cover or case are warped. Put the cover on good piece of glass and look for gaps use the smallest feeler gage you can get. if it's OK. put on cover on without gasket and see If any gaps or rocking the same way. If all is OK and it still leaks. Gasket sealer ??
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April 14th, 2015, 05:22 PM   #4
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If the cover is warped get lapping compound (auto parts store) and use the glass to lap it. I don't want you to not use the gasket. This is about last post. Use it. It will only work if its off a small hair. Can't tell but may be you could lap the case also.
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Last edited by Rainerio; April 14th, 2015 at 05:52 PM.
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April 15th, 2015, 01:13 AM   #5
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Thanks for the info guys! So i'm going to scrape off any derbris, check for warp, and then try to mount it again, first without gasket sealer, and then with gasket sealer if that doesn't do the trick.
Hope it works
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April 15th, 2015, 06:34 AM   #6
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As it turns out, cover or case is warped..
When i mounted the clutch cover without gasket i got no gap most places, and a gap of 0,10-0,15mm at the spot where the oil leak was. Went out and got a tube of gasket sealer, and will be trying this with the gasket.

Kind of a bummer this.. So i bought a husaberg without knowing the frame was cracked and the clutch cover was warped
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April 15th, 2015, 06:41 AM   #7
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Originally Posted by SnickaSnick View Post
As it turns out, cover or case is warped..
When i mounted the clutch cover without gasket i got no gap most places, and a gap of 0,10-0,15mm at the spot where the oil leak was. Went out and got a tube of gasket sealer, and will be trying this with the gasket.

Kind of a bummer this.. So i bought a husaberg without knowing the frame was cracked and the clutch cover was warped
That sucks. Try with gasket maker... if that doesn't work, figure out which is warped: case or cover.

Taffy sells all kinds of goodies... maybe he can help if you need a new part.

If it makes you feel better, I am stuck replacing the conrod in a used bike I bought (and I haven't even gotten the chance to ride it yet). Did an oil change after I bought it and discovered some major failure via chunks of floating metal. Oh well, fun all around.

Good luck.
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April 15th, 2015, 06:55 AM   #8
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Originally Posted by jmscrttndn View Post
That sucks. Try with gasket maker... if that doesn't work, figure out which is warped: case or cover.

Taffy sells all kinds of goodies... maybe he can help if you need a new part.

If it makes you feel better, I am stuck replacing the conrod in a used bike I bought (and I haven't even gotten the chance to ride it yet). Did an oil change after I bought it and discovered some major failure via chunks of floating metal. Oh well, fun all around.

Good luck.
Oh, well that didn't sound too good either I hate it when sellers hold back information, really sucks.
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April 15th, 2015, 06:57 AM   #9
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Looking at the picture just right of the markings, I am betting that is the spot where the leak is? Very hard to tell from a picture but looks as if someone has sanded it down. Air tool removal of old gasket I would bet. As noted prior, A lapping compound and wet/dry sand paper can work. Place the paper on a true flat surface. A good heavy piece of glass works well. place the paper on the surface and then the part. Apply even pressure on the part and move around to sand. This should true the surface enough to allow sealing. Pending on how far this is out?
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April 15th, 2015, 09:19 AM   #10
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Originally Posted by FE350 View Post
Looking at the picture just right of the markings, I am betting that is the spot where the leak is? Very hard to tell from a picture but looks as if someone has sanded it down. Air tool removal of old gasket I would bet. As noted prior, A lapping compound and wet/dry sand paper can work. Place the paper on a true flat surface. A good heavy piece of glass works well. place the paper on the surface and then the part. Apply even pressure on the part and move around to sand. This should true the surface enough to allow sealing. Pending on how far this is out?
We've got a detective ^^^

Great thinking. Likely the cause if the deformation is local.
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