another leak and do not know how to get to it

[Anonymous]

1980 GS850GL

Went and warmed up the bike for a ride today. After warming up I turned it off waiting for a friend. Next thing I have a puddle of oil under the bike.
I starting searching and it is coming from (lack of another word) behind the shifter cover. Looks like a breather hole. Well I stuck some rags in the very tight area to clean up oil. After it sat for about 30 minutes I started up again and only a drop or so. I rode about 50 miles stopped and only had two drops under the bike. Rode another 50 miles home and went out about an hour after the ride to a small puddle. I cleaned it up and went for a small ride and came back and nothing. What is this hole and why the random leaking and the varing size of the leak. thanks

[KEITH KRAUSE]

I think your "breather hole" may be a drain hole? On top the engine case, below the carbs, is a reservoir that channels any water down and out to a drain hole.
In the case with my bike ('79 GS1000), the o-ring seal around the starter motor shaft was leaking. This collected in the reservoir and drained out the drain hole (upper left) behind the shifter/sprocket cover.
If your bike is similar to mine, take off the cover over the starter motor and look for oil flowing where the starter shaft inserts into the case.

[bwringer]

It could also be a leaking cam chain tensioner, which is very common but easy to fix:

http://bwringer.com/gs/camchaintens.html

You might also check the photos and discussion on this thread, which may help you describe what's going on with your bike, too:

http://www.thegsresources.com/_forum/viewtopic.php?t=33621

(Keep going -- it's a long one...)

[dpep]

Re: another leak and do not know how to get to it

1980 GS850GL

I starting searching and it is coming from (lack of another word) behind the shifter cover.

When you say "behind the shifter cover" are you talking about down on the left side of the engine/transmission case just above the left footpeg? Because if you are it sounds like you are talking about the level checking hole for the middle gear oil. You have a shaft drive which has separate compartments to hold 90w gear oil at both the front and the rear of the driveshaft. That middle gear compartment has three plugs - a filler hole on top of the case, a drain hole located below it just above the shift lever, and the hole to check the level which is on the side of the case above the footpeg; this is a smaller diamteter hole filled by a screw rather than a plug. If that screw has come out, lube could be splashing out onto the engine case and then dripping onto the floor when the bike is parked in the same spot for a while. The 90 weight drips more slowly.

If this is what we are talking about, do no more riding until you have replaced the lube. The max capacity is only 13.5 oz, less than half a quart. It sounds like you have already lost a couple of pools. Just pour the 90 wt SLOWLY, a little bit at a time into the filler hole until it starts trickling out of the checker hole. It takes a while for the lube to get to the hole. Pour a couple of ounces, wait a few minutes, pour a couple more ounces, wait a few minutes, etc. until you seen the oil coming out.

If this is the hole you are talking about let us know, and I will get you the part number for the screw.

[Anonymous]

it is leaking from the mystery hole

Hi thanks for the Link.

ttp://www.thegsresources.com/_forum/viewtopic.php?t=33621

that mystery hole is where mine is leaking. Now I got all the part numbers for the cam tentioner. but it was said it could be caused by the a leaky o-ring on the stater neck. I can not find that on the fishe. Does anyone have that part number. also for the oil presure switch. Could not find that either. Guess I am looking under the wrong place. Want to order it all at the same time.

What causes this to leak ramdomly? I had it leak one time last year in 10,000 and then leak this time. Just curious.

thanks

[Anonymous]

Bwringers link was from a thread that I started. I may not have solved the problem yet (since I haven't had a chance to start and ride the bike yet). But while I had everything opened, and as noted in the thread, I opened the oil level hole for the secondary gear (right behind the "shifter cover") and drained a fair amount of gear oil out. I think my level was too high, thereby causing oil to come out the overflow canister and tube which drains down that mystery hole.

In my case, the gear oil was draining down the side of the engine and accumulating onto the exhaust crossover member making a big stink whenever the bike was started last summer. I have since replaced that short drain hose with a longer one that will deposit any oil behind the crossover pipe and between the pipes. But, hopefully, it won't leak anymore since I relieved it of its excess.

If it does leak, as bwringer noted, it may be from engine oil leaking into the secondary gear box, and if so, I understand I'll have my work cut out for me. :roll: Ah the Zen of it all!

Speaking of the Zen of it all, while you're in there:

Plan on replacing the side cover gasket.

You may need an impact driver to get the side cover screws off, and if so, replace them with stainless steel allen bolts.

Check the connections for the stator--mine were pretty charred and so I replaced them and coated them with dielectric grease. Clean and coat any other connections on the harness there too. You'll have to disconnect the stator to get the side cover off anyway, as well as open up the starter cover, as well as take off the carbs, tank, airbox, etc.

I did not replace the o-ring on my starter. It seemed fine and had a good seal when I pulled the starter out. Plus there was no oil from the alternator in the starter cavity. I just hit the o-ring with some silicone spray and then a fine coat of grease.

And if you really want to go for the gusto, check (and possibly replace) your shaft boot, wheel bearings, fork seals (mine leak) and dust covers, steering head bearings, clean and coat as many electrical connections as possible, and for good measure pull out your battery box, de-rustify it, and paint it nice and shiny black. Clean everything else you can reach while you're at it.

OK, I'm getting a little tongue in cheek, but that's not far off from my current spring project. Actually, it's pretty spot on.

Have fun, good luck, and keep us posted.

[Anonymous]

Mystery hole and gear oil

I think that is my problem also. How much did you drain out? I think that explains the random leak. Once last year and the year before. Just one time. When I changed and filled the gear box I filled it until I could see it via the fill plug. did not notice the oil level plug.

All the other stuff you mentioned, clean and paint battery box, airbox etc. Way a head of you, been their already done that. lol

[bwringer]

Re: it is leaking from the mystery hole

Hi thanks for the Link.
that mystery hole is where mine is leaking. Now I got all the part numbers for the cam tentioner. but it was said it could be caused by the a leaky o-ring on the stater neck. I can not find that on the fishe. Does anyone have that part number. also for the oil presure switch. Could not find that either. Guess I am looking under the wrong place. Want to order it all at the same time.

Scroll down a bit, and you'll find the part number for the starter o-ring:

http://www.thegsresources.com/_forum/viewtopic.php?t=35479

I can look up the pressure switch o-ring seal when I get home, or someone may chip in sooner.

[Anonymous]

how full??

well I opened the oil leveler and boy did i have it over full. Never knew it was their. My book said to fill up until you see it at the filler plug. Well guess they were wrong.

I decided to just drain the gear oil. When taking out the drain plug I notice a very badly worn o-ring/washer? Not sure what it was originally. could someone tell me if I am to replace that with an o-ring?

Now since I know I over filled the front with gear oil, what about the rear. How do I know how much to put in it? Might as well drain it and put new in.

Also I checked no oil in the starter housing. So I guess its burp is from having the gear box too full. thanks

[Anonymous]

My oil level plug for the secondary box had some half-arsed cardboard gasket on it, so I replaced it with a fiber washer from the local hardware store. Neoprene squished out too much.

I figure that once oil stopped coming out of the level hole, it was fine. I would assume the same would work for the primary gear oil level at the back wheel.

I'll get back to playing catch-up on my bike

[Anonymous]

is there a oil leveler for the back

Is there an oil leveler for the back gear box? If so, where is it located?
thanks

[bwringer]

On the "rear gear box" (on the rear wheel), you add gear oil until it starts to run out the fill hole. There is not a separate oil level screw.

On the "front gear box", you remove the oil level screw and slowly add gear oil until it starts to come out the oil level hole. The slower you go, the less mess. Allow the gear oil to continue dripping out the oil level hole for 20-30 minutes or so, then replace the fill level screw and the fill plug at the top.

[Anonymous]

WHY

Why do you let it run out for so long? :?