My FS650 is leaking from clutch cover.

SnickaSnick · Apr 14, 2015

Hello folks!

I just bought my H-berg FS650 2006(or 2007):happy: 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:unsure:

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!

jmscrttndn · Apr 14, 2015

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.

Rainerio · Apr 14, 2015

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 ??

Rainerio · Apr 14, 2015

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.

SnickaSnick · Apr 15, 2015

Thanks for the info guys!:happy: 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

SnickaSnick · Apr 15, 2015

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:furious:

jmscrttndn · Apr 15, 2015

SnickaSnick said:
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:furious:

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.

SnickaSnick · Apr 15, 2015

jmscrttndn said:
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.

FE350 · Apr 15, 2015

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?

jmscrttndn · Apr 15, 2015

FE350 said:
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.

KentJ · Apr 15, 2015

I'm no pro, but I would think that would seal up nicely with some Silicone RTV or another type of gasket maker. Since the oil behind the clutch cover isn't under pressure a properly applied sealant *should* take care of those imperfections.

Sealing the water jacket or an oil gallery would be different, but I'm voting for reinstalling with some sealant added.

PS, don't bugger up the kick starter on reinstall...

jmscrttndn · Apr 15, 2015

Really, don't bugger the kickstarter. Kent, myself, and many others have had issues with this. The manual doesn't explain how to re-install well. Ask here if you need clarification. Taffy helped me to re-install with photos and whatnot.

SnickaSnick · Apr 15, 2015

Ok, uhm. Thing is that most of the kick starter parts are in a box i got along with the bike, as last owner messed it up somehow and didn't manage to get it fixed, so i'm just gonna relay on the electric starter:rr: If it one day fails i'll have to admit defeat and walk home:furious:

Anyways I'm goin' to try this gasket maker first, hope it will be all good:happy:

I didn't tell you guys, but I already have drained the oil, drained the coolant, removed the clutch cover, changed the water pump gasket, mounted the clutch cover, filled 'er up with coolant and oil already three times before this problem even occurred :unsure: Man, that leaky weep hole was a real b*tch to fix. haha

SnickaSnick · Jan 10, 2016

I just tought I should give an small update, in case of any future people with the same problems:cold:. Gasketsealer didnt work at all. Might have been just me doin it wrong. The solution for me was to buy a brand new engine cover and mount that instead along with a new gasket and no gasket sealer. Worked great! No problems at all:happy:

Dr_C · Jan 10, 2016

Grinding the whole cover 0,1-0,15mm is a drag. Try putting the cover on a flat and hard surface (need a hole/cavity for the kick starter bushing?), and make sure the sealing surface is supported all the way around. Put fx a steel ruler (1-1,5mm thick) underneath where the cover still is straight, with only the part being wharped sticking out and not being supported anymore. Hold the cover firmly down and give the warped part a smack with a rubber/plastic mallet. That should bring it straight again. If it bends to far it's less of a worry. Either it will compress the gasket better than before, when you have tightened the bolts, or you can grind only that part of the cover. The supporting surface and the thin ruler will prevent you from breaking the cover or correcting it to much. Did that make sense to you?

SnickaSnick · Jan 10, 2016

Made a lot of sense, thanks! But as I just wrote I have bought a brand new cover, and the problem is fixed

Thanks though!

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