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Crankcase leaking water

Joined Oct 2003
955 Posts | 1K+
Sweden
Hi all!
This may come to you guys as yesterdays news, but feel free to ignore it in that case.

I had a 2001-2003, 650 crankcase that was leaking water into the oil. All sealing elements were in order and there were no signs of pores in the cast. After a lot of pressure testing I found it! The crank case halves were burred off too much where they are sealed together. Just around the area for the three o-rings on the sleeve, the sealing surfaces was almost tapered off on both case halves, making the o-rings job very difficult. I welded the cases in the specific region and grinded/polished them to sharp edges again. Voila! Tight up to 2 bars, without loads of liquid gasket. But you all knew that one, didn't you? :wink:
 
i had mine leak at the three 'O' rings like yourself after i'd run it without water for a whole race. i guess i was lucky that a bit of silicon and it was sorted second time around.

regards

Taffy
 
After a very hard two day enduro in which the bike boiled over a few times, water has got into the oil and the bike will not start. This sounds like the same thing as you've experienced. Where abouts are these three O rings and is it an easy enough job to do.
 
The o-rings are located around the lower part of the cylinder liner. You have to split the engine "completely" to find them. If the engine has been overheated, the o-rings might have gone "square" and lost their preload. If the bike will not start you have propably more problems, I'm afraid. You will need some experience around engines and at least a special flywheel puller to manage. But if you are a patient and thorough man, nothing is impossible.

Good luck!
 
i'll kinda disagree with you there DrC. the bike needs a rebuild and that's all thats wrong as regards tthe starting. i don't even think that it has to be the 3 O' rings why he lost his coolant.

i think it's a headgasket. could be a waterpump seal or you have a puncture in the rad or a pipe. 1 and 3 are my favourites.

just got to do the hard miles i'm afraid keiran!

look at 'Taff''s racing season - 2005' it's in the racing forum and the month is july. i describe losing the coolant and the rebuild requirements. so i've been there too!

regards

Taffy
 
Taffy said:
i'll kinda disagree with you there DrC.
Don't I have to state something before you disagree? :)

Anyway, it needs to be taken apart and investigated.
 
The racing history this year involves: 2005 Fe550e
Oct-Bike boiled up water leaking out water pump, changed seals never leaked again. Oil fine bike running.

March-Boiled up water leaking out head gasket, changed hopefully no problems head checked and not warped. Oil fine bike runs

July- boiled over, fluid loss all from radiator overflow, lots of steam. Water not leaking from weep hole or head gasket. coolant pipes/rad seem ok. Oil contaminated, oil and water in airbox/frame. Bike won't start.

What do I check next? Water pump seals seem ok but will change, O ring on LHS casing seems ok but will change. Not easy to check the cylinder liner O rings
 
Remove the transmission cover. Plug the water stub out from the cylinder head (attach a piece of hose with a plug in the other end). Use compressed air into the water hole from the water pump into the cylinder. Apply pressure carefully and try to listen for leakage. You should be able to determine if it´s coming from the cylinder liners o-rings.

Good luck!
 
i know what the problem is. 100% no ifs or phuqing buts!!!!!

you are getting compression in the water system and there is only one place in the engine that pressurises the water.

that's why it waits and then gets ya!

this time make the head cleaner, the block cleaner and if you want to be honest i think you need to strip the engine and re seal the three 'o' rings if you've touched them. if you really really want my opinion i would skim the block and leave the spigot proud ala the mod in engine rebuild in the doc.

regards

Taffy
 
Thanks for the advice, looks like a rebuild then. How much should it cost?
Where do you get stuff like the head skimmed done? If I'm going to have to split the cases I'm going to have to get a mechanic to do it. What exactly do I need to tell him? Head gasket and probably a warped head/barrel and maybe the 3 O rings. Anything else?
 
ok keiran

read this one and weep!

as far as who will do it well the island still has plenty of motor engineers about. go to

e b christian
mylchreests
or a bike dealer

and ask who they use.

took me 20 minutes to find this but here it is:
http://www.husaberg.org/index.php?name= ... highlight=

i'm trying to think of a way of coming over all expenses paid, getting drunk in the quids in, doing a lap of the TT (sober) and building your engine for you but i refuse to sleep outside with the dog!

there are loads of mechanics over there that would have a go at this given all the information. you only need a flywheel puller otherwise a good mechanic can have a crack at it.

don't order parts till it's apart.

the only thing you can do before the full strip is to check that you had the head torqued to the higher figure (shown in the doc under rebuild) . otherwise i feel you have found the problem here.

also go into vikings gallery and check that you don't have a problem at the radiator cap like he did?

regards

Taffy
 

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