clutch basket cover oil leak not fixed after gasket change- now what?

shift_enter

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I have a slow oil leak from the clutch cover and I replaced the gasket and still have a slow leak. I cleaned off the residue of the old gasket very well to ensure a good seal. should I try some liquid gasket stuff? If I do, do I need a brand new gasket each time the cover is opened? it’s a fairly slow leak so I just have to carry oil with me on longer trips. I am the second owner and the previous owner did do some off-road riding, but the cover has no indication of damage or impact which would cause this leak. it’s difficult to take photos of the area but I indicated around which bolt it’s leaking.0EEECF1E-CAA1-4F72-A6FB-97DC8122C84C.jpeg
78443DD2-05C8-464B-A9CC-A69CCB8B563A.jpeg
 

~TABASCO~

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Are you on a gen1? My memory is lousy these days but didn't the gen1 bikes have an issue with a dowel being too long on the side cover and the cover can fracture?
Yes. !!! The pin it to long. They need to get two new dowel pins. And a new gasket, make sure that gasket ‘maker’ has not found its way into the motor.
 

Kurgan

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Yes. !!! The pin it to long. They need to get two new dowel pins. And a new gasket, make sure that gasket ‘maker’ has not found its way into the motor.
First I've heard of this. Any chance you know the difference in length between old and new? Was wondering if it would just a matter of chucking up that dowel and removing a few thousands or just order the dowels from a......2014 or newer model?
 

shift_enter

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Yes. !!! The pin it to long. They need to get two new dowel pins. And a new gasket, make sure that gasket ‘maker’ has not found its way into the motor.
OK I’ll order a new gasket and new dowel pins… Do you think there’s any chance I could just grind down the ones I have now? Stead of ordering new dowel pins?

and what do you mean by maker?
 

Kurgan

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I've not seen the gasket for the clutch cover on the S10, but on other bike's where I've pulled the clutch cover.....Vstrom, ZRX1200's, Hayabusa, etc.....I was shown an old school trick which worked well..

Take a new clutch cover gasket and apply a thin even coating of anti-seize on both sides. Wipe it on with a gloved finger tip so there's no real thickness to it and bolt up that cover. I was able to pull that cover off and reinstall it 3x on the Vstrom without any damage to the gasket and it sealed perfectly.

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First I've heard of this. Any chance you know the difference in length between old and new? Was wondering if it would just a matter of chucking up that dowel and removing a few thousands or just order the dowels from a......2014 or newer model?
Yes. You could chuck it up and take off a few thousands. It was only on a few early bikes. But that IS the issue.
 

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OK I’ll order a new gasket and new dowel pins… Do you think there’s any chance I could just grind down the ones I have now? Stead of ordering new dowel pins?

and what do you mean by maker?
It would be OK to take a bit off the pins. Just make sure the leading edge has a nice chamfer so it doesn’t mar the case bore.
Maybe I miss read, I thought someone said they added gasket maker to the original gasket. Make sure that’s all cleaned up when re installing. New gasket - nothing extra :)
 

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First I've heard of this. Any chance you know the difference in length between old and new? Was wondering if it would just a matter of chucking up that dowel and removing a few thousands or just order the dowels from a......2014 or newer model?
I personally don’t know the difference. I have a feeling they are “supposed” to the same length. A few got out that are to long.
 

jrusell

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Stock dowel pin is 21mm long.
I had a slight weep on my cover. When I was in there to do the tensioner I shortened it 1mm to 20mm. No issues yet.
I had to remove my cover shortly after putting in a new one. I Just used a bit of RTV in the areas where the new gasket had the grey sealant applied. No issues with leaks on my reused gasket.

I do not know if the issue was too long a dowel or possibly the hole was not drilled deep enough. Just shorten your dowel and reuse your gasket.

C122E85B-0F6D-4095-BC04-69426AFBD39F_1_201_a.jpeg5FB9BFB0-1E36-4673-8DBF-2D7CB31C1ABA_1_201_a.jpeg
 

Tenman

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Seems like they would leak on the showroom floor if it was too long. I went in a Harley dealer in the early 70's. They had pans under 2 new badass looking sporsters. I swore off Harley's for good when I saw it.
 

jrusell

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Stock dowel pin is 21mm long.
I had a slight weep on my cover. When I was in there to do the tensioner I shortened it 1mm to 20mm. No issues yet.
I had to remove my cover shortly after putting in a new one. I Just used a bit of RTV in the areas where the new gasket had the grey sealant applied. No issues with leaks on my reused gasket.

I do not know if the issue was too long a dowel or possibly the hole was not drilled deep enough. Just shorten your dowel and reuse your gasket.

View attachment 71203View attachment 71204
Sorry my error 20mm stock, shortened to 19mm.
 
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