Topic: Oil Leaks

[Zeke]

My newly rebuilt bike is running awesome.

When I put it back together, I was very careful about gaskets/o-rings and such.

I used hylomar in a few places (base gasket around cam chain area, and top side of head cover oring) and a dab of Hondabond as described on this site aroung the oring seals on the oil passages.

I have oil leak issues though.  There are 22 bolts that hold on the head cover.  2 of those bolts are right at the extreme right and left, at both ends of the cam, right in the middle.  There is oil coming up and out of those bolts under the washers, mostly when it's cold but continuing while riding.

I lost some of the original washers that appeared to be a plated copper now that I think about it -- is it possible that these are sealing washers?

I was going to try putting them back on but one of these bolts began to strip out when I was torqueing it in -- so to remove the bolt would mean I'll have to remove the head cover and helicoil it.

What do you think?

I rode her 600 miles this week to work and back every day -- there was some extended high speed riding in there -- maybe 30 minute periods of 75-80 mph.  Do you find you have more leaks at high-speed?

Zeke

[scondon]

Hey Zeke,

       I don't know what bike/engine you have so can't say whether missing washer is an issue. On the 750 engines I have done there were no washers on the valve cover screws. I can say that any bolt that starts to strip on reassembly WILL leak. Same thing happened to me, I had the engine 99% put together and one of the last two bolts(valve cover)stripped. I didn't want to go through the hassle of pulling everything apart, taking the head to be helicoiled, and springing for another head gasket, so I just let it be. Later in the life of this engine, one of the bolts in the spark plug recess began to pull loose and the head gasket blew. I am now of the mind that ANY stripped bolt should be taken as a sign of weakness/fatigue of the head and should be addressed before installing the engine. I'm not saying that your engine is going to blow, just relating what happened to me. And yes, higher speeds/ operating temps meant more oil weeping out. Hope this helps.

[bryanj]

Those are sealing washers on the bolts to stop leaks so itf the threads are bad you will have to pull the valve cover and helicoil. At least its an in the frame job unlike the 750. There should be a washer above the braket (steel) and a washer below the bracket(sealing). At least you know the cam is getting oil!!

[Robert]

Try to get some washers in the right size (ID: 6mm = 0.24 in and OD: 11mm = 0.43 inch or slightly bigger, thickness 1mm = 0.04 IN).
To the best of my knowledge these washers are made of aluminium. Propably copper works too, but would require more torque to seal -> threads in danger. Those threads are sensible.

[Zeke]

Yeah sorry all -- its a 650.

I guess those are sealing washers.  I wasn't really using my noggin when I replaced them with regular steel washers.

So, to fix it right I do need to pull the head cover to helicoil.

I'm sitting here wondering why no one ever invented a screw designed for such a repair -- where it's just slightly bigger and self-tapping so you just screw it in.

Oh well.

Zeke

[Zeke]

OK, now that I'm gonna have to to this....

Helicoil, or Threaded Insert?

I've never used a helicoil and I'm always leery of these things.  I don't want to mess with this again.

Do helicoils use a special tool?  What should I watchout for to make sure I do it right?

Thanks,

Todd

[Einyodeler]

Todd
Check these out:
 
 http://www.roadstarmagazine.com/modules.php?name=News&file=article&sid=233

http://www.toolsnextday.ltd.uk/Helicoil_Kits/helicoil_usage.htm