Oil Leak

ROWLEY · Jun 14, 2004

Hi all

Had 2 great rides over the weekend on my 02 650 SM. Got back to notice oil had been running down the back of the engine - and had been splashing onto the rear shock/swing arm. It appears to be coming from behind the battery area? Is there a seal or similar in the starter motor region that could be the culprit :?

Previously fixed the transmission cover leak - just a tiny drip now. So a bit chaffed-off about the new one (probably was already there though :? )

Your help is much appreciated as always.

Rowley

Taffy · Jun 14, 2004

you have two seals, the first is as you say for the starter motor and the other is for the kickstart decomp shaft. you also have the camchain tensioner block to think of.

Taffy

fontana302 · Jun 14, 2004

I'd bet it'll be coming from the kick start decomp shaft - there's no seal there. This is a design fault for mine. The fix is to pull the side cover and decomp mechanism out, spot face the case and fit an o-ring to the decomp shaft.

I also had leaks there, from the water pump, rocker cover, cylinder head and oil filter cover on my 650.

ROWLEY · Jun 14, 2004

Decomp Shaft etc

Is there no gasket/seal at all? What does 'spot face'mean?

Thanks chaps!

Rowley

berger · Jun 14, 2004

The kick start decompression device on my bikes is just a seep or very small leak. If it is a large leak you may have a clutch cover leaking back by the shifter shaft. Have you checked for a crack in the rear of the case where the swing arm bolt goes through (I hope this is not the problem)?

ROWLEY · Jun 14, 2004

A Crack!?

Berger

....I hope the same

Rowley

twistthethrottle · Jun 14, 2004

Rowley, if it is the kick start decomp shaft (it usually is) there is no seal fitted at the factory. You don't need to strip it down to fit one.

I have copied the steps below, they were my response from a previous thread.

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 in Sweden. The oring was their suggestion.

ROWLEY · Jun 15, 2004

YO 'TWISTTHETHROTTLE'

Thanks, your advice is much appreciated.

Unfortunately, I spent last night stripping things down to get to the said shaft. God I wish I hadn't bothered now, but I'll have a look inside anyway to see if there's room for an O ring in there etc (so long as it causes no other issues etc.). Otherwise I'll use your 'proven' method.

I know I should have waited. I've got all new gaskets/seals on order re w/pump and cover etc.

At least I had a great blast last weekend eh!

Thanks again

Rowley

chris · Jun 15, 2004

Rowley,

I'm from ipswich too and had the same problem a couple of weeks ago.... Let me know if you fancy a blast one evening. Also practice days....

Unfortunately for me my casing was cracked,

and the last two weeks have resulted in a major rebuild as splitting the cases is such a major job it would be folly not to replace all the bearings and gaskets. I do hope for your sake that it is just the decomp lever. Mine still leaks slightly so i will probably try the oring fix.

Although off topic i did manage to get all the bearings and bits within 3 days and get the casing welded up so i was only off the road for a week. Full marks to Jim Aim Motorcycles and Dave Clarke.

Chris

fc600 Supermotard

ROWLEY · Jun 15, 2004

CHRIS

Hi Chris

It looks just to be oil seeping out from around the the shaft - but there's plenty around after a good blat! I'll maybe get it done this weekend :? My last ride rekindled my enthusiasm for the Berg after 3 weeks in the garage when time allowed etc

(you obviously know what I mean!). I've had the trans cover off more times than I can remember - fixing the w/pump seal twice/counter balance O ring, and just the trans cover oil leak. Then there was the carb to sort and the crankcase breather is remedied. I can do the trans cover blindfold - so last night I done it again! I've had enough at the moment

Anyway, the following weekend I'm off to Assen for the GP. It'll be great to meet up when I get back. Maybe you wouldn't mind giving me some riding advice. I have yet to do a SM school, but I plan to

.

Regards

Rowley

twistthethrottle · Jun 15, 2004

Re: YO 'TWISTTHETHROTTLE'

ROWLEY said:
Thanks, your advice is much appreciated.

I'll have a look inside anyway to see if there's room for an O ring in there etc (so long as it causes no other issues etc.).
Rowley

Rowley, sorry but the oring has to go on the ouside. As you'll see, the decomp is rotated as the kick start is kicked down, on the return, the decomp shaft actually slides out of the engine casing about 10mm. Because of this, it is not practical to fit a seal on the inside of the casing.

Just to make you feel a little worse, if you had done a search on decomp or oil leak you would have found the previous thread on the problem, it was only last month.

Good luck with it.

fontana302 · Jun 16, 2004

Not True,

Spot facing the casing is required to fit the o-ring on the inside - works great. Ask Caldecott he knows all about it, so does Husaberg Australia they did mine under warranty after I brought it to there attention and told them how to do it. It's a bit more work but worth it in the long run.

Regards

twistthethrottle · Jun 16, 2004

No problem Fontana, I didn't say it wasn't possible, just not practical.
The fix I outlined only takes 20 minutes, costs 10c. In my case its been almost 2 years and hasn't leaked.

I didn't realise Caldecott rode a Husaberg, I thought KTM had been sponsoring him?

LuKe · Jun 16, 2004

Your right Brian but Caldecott also has a Husaberg Dealership in Keith South Australia.

Oil Leak

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