Coolant Leak

Maddog · Oct 8, 2009

Problem Solved

Hey fellaz.
Well I drained and flushed the coolant out of the system.
Filled it will the Seal Up and distilled water.
Let all the air out using the bleeder screw.
Fired her up and took her for a 30 min ride.

Here's the result

Not a drop leaking, Whoohoo!

It was leaking as soon as the bike was warm so this is a good sign.
When I got back I drained the system and I've let it sit over night to cure as per instructons.

Tonight I'll refill the system with new Motul coolant and all going well, this leak will be permanently fixed and no other problems will arise from using the stuff.
All I have to do now is get rid of those chicken strips left by the previous owner :lol:
There already getting smaller :wink:

Thanks everyone for all your help, much appreciated.

Maddog · Oct 9, 2009

Spoke too soon!

Well fellaz looks like my troubles are not over.
I filled the bike with fresh coolant, bled the air out and fired her up.
It wasn't long before coolant/oil started seeping out of the damn weep hole.

F*ck these bikes are finicky!

So I'm off to read all the weep hole threads to find out how to fix this this.

bushmechanic · Oct 9, 2009

RE: Spoke too soon!

bugger!

its like the old tractor, fix one leak and the higher pressure blows out somewhere else

the fix it stuff might have upset the water seal maybe

you should be able to replace it without taking the clutch cover off if you can get the old one out

its a 10x18x4 but a 10x18x6 will fit.

Maddog · Oct 9, 2009

Thanks Bushie.
I'm heading down to CBC now before they close, they've got the 6mm wide in stock.
I'll grab a couple I think.
Haven't tried to get the old one out yet but I'll let you know how I get on.
Thanks again mate.

Maddog · Oct 10, 2009

Well there was no way I was gonna get the old WP seal out without removing the Side cover.
I really didn't want to damage it's housing by poking around and trying to dig it out.
So side cover needed to come off.
Had to disconnect the exhaust so I could get at a couple of the top bolts too, what a drag.
I made sure I held the kick starter shaft in as well when I did it.

I was getting some oil out the weep hole as well so really wanted to take a look at the oring on the shaft that runs inside the bearing.
As you can see from the pic the oring needs replacing because it's hard as a rock, pitted, flat, and moves freely around the shaft.
Also the shaft where the WP seal runs is a bit shabby so I'll clean that up with some wet and dry.
The bearing looks to be in good nick, it's sealed on side and moves freely so I'm leaving it in. That shouldn't be a problem I hope.

Hopefully get her back together today if I can find a new Oring on a Sunday, otherwise will have to wait to get the right size one in.
It's been great weather for riding down here so it's been a real pisser to have this girl off the road.
Haven't really had a decent ride on her yet since buying her but she needs to be up to spec before I can give her a good flogging. :wink:
I'll keep ya posted.

Maddog · Oct 11, 2009

All back together and no leaks!

Hey fellaz.
Well got her all back together and all looks good so far.

I cleaned up the shaft and used a generic seal 18 x 10 x 6mm. It's a bit wider than the stock one but that can only be a good thing.
It fitted fine and I used a little sealant around the outer edge before pressing it in.

I picked up an o-ring from the local auto parts store and I reckon it was about 2mm thick instead of 1.25mm.
It was a snug fit into the bearing when I put the cover back on but I greased it pretty well so hopefully I didn't nick it in the process.
I took her for a 20 min ride afterwards and no leaks from anywhere especially the weep hole.

All in all cost me $5.50 for the seal and I got the o-ring for free.
I used the old gaskets because they were still in good condition so it was a cheap fix and a pretty easy one labour wise.
I made sure I got an extra seal and o-ring too for next time this **** happens.

I think this design with the weep hole, WP seal, and shaft o-ring inside a bearing etc is pretty weird, but there must be some logic behind it.
I don't like it though.

Coolant Leak

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