This is the second time this has happened. I drain the primary fluid, check the chain spec, adjust the clutch pack, and add new fluid. All goes smoothly. The bike shifts perfect, goes into neutral perfect, but when I finish my test ride, I see a smear of fluid that's weeping out from under the primary chain inspection cover. I used a brand new gasket and even bought a nice new inspection cover, but it still leaked. I even went all out this time and bought a new torque wrench.

The first time this happened, I just wiped the small film of fluid off the primary after each ride and didn't do anything to fix it, because it was such a small amount of fluid. This time there is a little more fluid and it's bugging the hell out of me.

I'm thinking about trying two gaskets or possibly putting a tiny bead of clear silicone around the cover, but I really shouldn't have to do that. Anyone have any good suggestions for me.

Thanks in advance for the info.

 

Did you inspect the seating surfaces (primary and cover) really good? Sounds like you may have a scored surface. If that is the case (no pun intended) you may be able to fill a gouge if you have one. Something else you may try is to use a gasket tac like that made by loctite. I swear by that stuff... gaskets stay in place, so there is no slippage while you are aligning the primary cover; this is another area that may be giving you trouble... if you have the cover drop a little "out of true" (it dont take much) before you torque it in place. I hope some of these suggestions help you out man.

 

I was thinking the same thing, gasket might of gotten pinched or not set correctly.

 

This is just the small inspection plate cover that's held on with four small allen head bolts. The manual says to tighten them to 80-108 inch pounds. I went with 95 inch pounds. Because it's so small, it would be really hard to mess the gasket alignment up. The mating surface on the primary look perfect, but obviously something is not quite right. I might try using thread sealant on the four bolts and may be put a bead of form a gasket on the primary surface and let that set up before installing the cover with a new gasket.

 

I tighten top, bottom Le, Ri. I do 50 in lbs 1st then go to 95 to 100 in lbs

 

check the bolt holes in the primary cover and see if they go all the way through. if they do, fluid is seeping out the threads. put a small dab of silicone sealer on the screw threads and the problem should be gone.

 

Thanks for the advice guys. I will stop by the dealer today and pick up a couple of extra gaskets and do a little experimenting. I noticed my old gasket had a silicone compression bead on each side of it. The gasket I bought at the dealer is just a really thin fiber gasket, which may be a little more difficult to get to seal properly. If all else fails, I can always get a sheet of .125" thick cork gasket material and cut my own. Using thread sealer on the bolts is probably are really good idea also.

 

If I torque mine over about 85inch lbs it will leak. I would get a new gasket, and torque to the minimum setting.

 

sometimes the washers on the bolts crack.