Ugh dang it, a leak

[Guest]

Crap, found a leak under my clutch cover this morning in the shop. I had installed my new clutch springs and cleaned the gasket surfaces and installed a new factory gasket as well....grrr. Haven't even started it yet

[Guest]

Crap, found a leak under my clutch cover this morning in the shop. I had installed my new clutch springs and cleaned the gasket surfaces and installed a new factory gasket as well....grrr. Haven't even started it yet

The gasket may of slipped off during installation. I use a little silicone (a see through film) on the engine case and put the gasket on the dowels and let it sit for a few minutes.

[Guest]

The gasket may of slipped off during installation. I use a little silicone (a see through film) on the engine case and put the gasket on the dowels and let it sit for a few minutes.

Nope gasket didn't slip off. It was on the dowels plus I had a bolt through that part so it wouldn't slip. It is right under the sight glass between the two bolts. One little bitty spot.

[Guest]

Nope gasket didn't slip off. It was on the dowels plus I had a bolt through that part so it wouldn't slip. It is right under the sight glass between the two bolts. One little bitty spot.

You may have some slight warpage. Try a little silicone. It won't hurt if used properly.

[Guest]

You may have some slight warpage. Try a little silicone. It won't hurt if used properly.

Now that could be. Thing is I don't want to break the seal on it again. It took a few trys on and off to get the clutch lever set right.

[Guest]

Just get the splines to mesh on the inside of the clutch and move the acuator lever to the right spot.

[Guest]

Just get the splines to mesh on the inside of the clutch and move the acuator lever to the right spot.

Did that, it was either too far in or too far out when I tried to align the lever. Had to get the splines just right to able to align lever in the right spot. I've done this a few times before.

[Guest]

That may be why it's leaking, the gasket is probably crushed and has a memory now of it being torqued, you may have to re-torque it slitghtly higher, or like he suggested, add some silicone to the mating surface, also, you shouldn't have to remove it to adjust your clutch, I back off the clucth adjustment and count my turns, remove the clevis, after I install the case cover, I twist the clutch shaft fully counter clockwise, re-install the clevis, and re-adjust back the same number of turns, and almost always right back where I had it, if not super close only needing minor adjustment.

Gasket was never torque, just snug down enough to check the action of the clutch springs and I used the old gasket for that. Once I checked the springs, the new gasket went on, then aligned the lever in the right position, then torqued the cover and gasket to specs. I'm thinking a dried out gasket or even not thick enough. I got it off ebay and it wasn't sealed. Didn't look like the old gasket either, the one I took off I know was a Suzuki part, it was a tan color where this new was gray in color.

[Guest]

Take the lever off its splines and put it in the correct position.

[Guest]

Take the lever off its splines and put it in the correct position.

IT is in the correct position.

[Guest]

IT is in the correct position.

What I am trying to say is you don't need to get the lever in the correct position while mating the inside splines. Just take it off after sealing the gasket and put it in the correct position. It's a pita to get it in the perfect position.

[Guest]

What I am trying to say is you don't need to get the lever in the correct position while mating the inside splines. Just take it off after sealing the gasket and put it in the correct position. It's a pita to get it in the perfect position.

...........

[Guest]

Think I found the cause of the leak, Took the clutch case back off and measured the thickness of the new gasket and compared it to the other gasket, The new gasket was a bit thinner. So, with that, Friday gonna order a new OEM gasket among some other stuff from Boulevard Suzuki sale.

[Guest]

Since I installed the new clutch cover gasket, leak is fixed. No seeping or anything. I did go back and look over the stock gasket and the one I ordered off ebay. The new stock gasket was flexible and soft to the touch, where as the one I took off (from ebay) was hard and barely flexible. The ebay one I bought was cut from a computerized gasket cutter and used a gray type gasket material. Could have been old and or dried out since it wasn't sealed when I got it. Anyways its all good now. Guess that tells ya something about stock gaskets. Oh yeah did send a note to the ebay guy I bought the gasket from. Go figure no reply.