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Water mixing with oil - Help!

S

sgomes

Joined Apr 2014
101 Posts | 11+
Alameda CA
Hey guys, well I'm kinda new to bikes after wrenching on cars for years; and, just completed the Orangeberg fix, only to find water getting into the crankcase.

The fix seemed without incident - new seal and bearing went in easily enough, replaced the water pump O ring, used the shrink tube when replacing side cover, new side cover gasket, new water pump gasket. No oil in coolant. Only ran the bike for a few minutes, but nothing coming from weep hole.

Any ideas on what I should look for when I pull the cover again?

Thanks.

Steve
 
there is an oring on the water passage seal between the clutch cover and the crankcase

maybe something to check
 
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After posting, I noticed that the replacement cover gasket actually had a tab that appeared to be overlapping the O ring. As can be seen here, I have trimmed away some of the gasket material, and applied Permatex.

I am still a bit uneasy, as it seems that the cover gasket should include a piece completely encircling the coolant passage. That way when the cover draws up tight, the passage perimeter will first contact the O ring, and then completely seal as the casting finishes against the gasketting all the way around. But, hopefully this will work.

Okay, I will confess that I am not the neatest, being old, fat, and a little sight impaired; but, this blown up pic makes it seem much worse than if one were looking at it from 20' away!

Just sayin.

Thanks for the tip.

Steve
 
hey Steve no worries

the o ring also looks like its a bit flattened, if it still leaks a new one might be worth trying

cheers
Bushie
 
Thanks for getting back. Actually, that is a new O ring that I've smeared with sealant, and it sits well above the plane of the casting; so, hopefully that was the problem.

And, I want to thank you for your many, many postings that have helped me, and no doubt a very large crowd of others.

The time and effort you take must be huge, and it should be acknowledged.

Steve
 
the O ring needs to be 2.2mm minimum thickness mate. stick the vernier on it and see what you've got?

Taffy
 
Taffy, Yeah, mine measures 2.4mm, and the one that came off was 2.0mm - looks like that was the prob.

Tks.

Steve
 
I don't know that smearing sealant on the o-ring will have any effect, besides potentially generating debris. O-rings are meant to generate sealing pressure primarily from being compressed btw 2 surfaces, and should maintain this sealing pressure over a long time (years). I would personally recommend against applying anything to the o-ring except perhaps grease so it can seat easily. Just my 2 cents. This particular o-ring (if it's the same one as my 05 FE550) is available for cheap from Mcmaster-Carr. Look up the dimensions in the manual and you can find it on Mcmaster.
 
Tony, I have since cleaned it off. I will tack it in place in a few spots, just to refit the cover.

Thanks.

Steve
 
don't know if this happens much anymore but if you ever get stuck out in the bush with a broken gasket or oring on a machine you can make one out of silicone

you need some bits of paper, plastic or old gasket 0.2-0.4mm thick, apply a generous amount of sealant and put it together with the thin paper spacers in non critical spots to hold the 2 surfaces apart 0.2-0.3mm bolts need to be loosely tightened

after its fully cured you remove the spacers and tighten it up
 
Nice tip, that, Bushy.

Well, I am having difficulty fending off frustration, because the crankcase still fills with coolant!! I have now had the cover on/off several times; and even though I am using the Orangeberg shrink tube to help protect the brown water pump shaft seal, which seems fine, I guess I should replace that as well as the shaft O ring.

Does the seal just pull out from the front?

Oh, also, there is now a few drops of coolant coming from the weep hole. I'm not even sure how that can happen??? Grrrrr.

One tip I have discovered (likely known by all others!!) - If the clutch cover is difficult to separate from the motor, one can remove the outer clutch cover, and then partially replace those 4 collar screws and 1 or 2 of the water pump screws just a few turns. Then use those screws to help walk the clutch cover off the motor, stopping every few mm to lightly tap the kick starter shaft back into place.

At any rate, I would appreciate any other thoughts on my coolant leak.

Thanks again guys.

Steve
 
Last edited:
i think the water can only get into the engine through the pump in any significant amount if the water seal is leaking and the weep hole is partly clogged .. dust dirt etc

apart from the big o ring you replaced there is only the head gasket and the orings on the bottom of the liner seal.

I have pulled the water pump water seal out the front a few times
 

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