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Message started by Jazzdude on 04/05/05 at 21:05:56

Title: Questions about the oil leak repair process
Post by Jazzdude on 04/05/05 at 21:05:56

Now that I've fixed the fuel problem on my bike, I'm ready to fix the infamous "head seal cap oil leak." It seems to be leaking more every time I go for a ride so I've decided it's time.

Question #1: Is it necessary to pull the engine from the frame in order to remove the head cover? I'd rather not have to pull the engine if I don't have to. I've heard both yes and no and I'd like some of your thoughts on this.

Question #2: If I don't have to pull the engine, what's the best way to torque the bolts when re-assembling the head cover? I've looked at the top of the head cover and there's not much room for a torque wrench.

Thanks for your help!
--Jazzdude

Title: Re: Questions about the oil leak repair process
Post by Reelthing on 04/06/05 at 04:35:46

Just did the process on a '95 a few weeks ago.
First you read over this tech doc.
http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1099227295
No, you do not need to pull the engine, but be sure and print out the bolt template as I didn't understand it's value until I used it - I'm not sure even 2 bolts are the same length and you'll be pulling a dozen or so. I just removed the seat and the tank (of course on this '95 to remove the tank you must drain it and remove the fuel petco-ck. Two things putting back together I seem to have botched - make sure when you put the vent hose back on it is not kinked or bent in any way and try not to stuff the stainless steel screen into the head cover very tight - this two things botched enough will lead to another leak in the speedometer cable - see post -
so far as torque - I have a 10mm openend head that fits a small 3/8ths drive needle torque wrench works ok on most bolts - a 1/4 inch drive click type would work better - but the top bolt was tighten with a 10mm shorty boxend (wrench is 3 inches long) and I might have used a 4 inch 1/4in drive ratchet on a couple of others - just be careful - these bolts need very little torque 7 or 8 lbs max - 5lbs would do I bet - so use small wrenches

Title: Re: Questions about the oil leak repair process
Post by Greg_650 on 04/06/05 at 05:16:03

Reelthing wrote:

Good advice. All of it.

But what really caught my eye is that you state that on your '95, the tank can't be removed without removing the petc0ck.....

We were trying to follow that issue in another topic and it disappeared. I think that the subject stopped with a measurement across the frame of 140 MM at the petc0ck. How wide is yours?

Title: Re: Questions about the oil leak repair process
Post by Reelthing on 04/06/05 at 06:27:27

I'll pull the tank again in couple of days and measure the frame, I want to have a look at the ngk iridium plug after 500 miles - curious on the color with this 150 jet and bit less than 1/2 the spacer and a touch of castrol tts 2-stroke oil in the gas - bike seems to run mighty fine.

Title: Re: Questions about the oil leak repair process
Post by erikrichard on 04/08/05 at 10:30:22

About that bolt at the top...my wrench stripped it, and I had to resort to visegrips to get it off. No way to torque it, thats for sure, but I put it back on with visegrips and no leak anywhere.

Title: Re: Questions about the oil leak repair process
Post by Greg_650 on 04/08/05 at 10:59:13

erikrichard wrote:

About that bolt at the top...my wrench stripped it, and I had to resort to visegrips to get it off. No way to torque it, thats for sure, but I put it back on with visegrips and no leak anywhere.

That bolt is difficult to reach and if using a wrench an open end is not a good choice. Once, working on a friend's Savage, that same bolt seemed too tight and wanted to round off. Since you can't get a ratchet in there, I found a 10 MM 6 point socket and ground 2 flats on the socket. Then I used a larger wrench to turn the socket and remove the bolt.

Title: Re: Questions about the oil leak repair process
Post by Jazzdude on 04/09/05 at 17:12:10

Thanks for all of the info on this. I'm on vacation and will tackle the leak when I get back. I plan on doing quite a bit of riding this summer and want to fix the leak before then. :)

Title: Re: Questions about the oil leak repair process
Post by slavy on 04/09/05 at 19:21:11

My investment was 1/4 inch drive 10 mm Craftssman swivel socket . Works like a charm with 6 inch extention.

Title: Re: Questions about the oil leak repair process
Post by Jazzdude on 04/09/05 at 20:51:31

slavy wrote:

My investment was 1/4 inch drive 10 mm Craftssman swivel socket . Works like a charm with 6 inch extention.

Sounds like a good combination to me. What type of torque wrench so you use? A needle or a click-stop? I've got a Craftsman 3/8" click-stop that, hopefully, should work.

Thanks, Slavy!

Title: Re: Questions about the oil leak repair process
Post by Spoccie on 04/11/05 at 06:23:51

Hi All,

I'm a proud Savage owner for a few months now.
From the beginning I knew my '87 bike had the infamous Head Seal Cap oil leak.
But recently the oil also leaks from a completely different spot then where it usually is. Now I'm worried that it's a different leak then the Head Seal Cap oil leak.
On this picture you can see where I found the oil dripping. http://www.geocities.com/master_in_the_force/SavageLeak.jpg

The leaking only occurs after I've been driving, so I guess it has something to do with the wind gushing through there.

Is there someone who could help me?
I'm a noob if it comes to Motors, but I'm eager to learn.

Cheers,

Ale Pieter

Title: Re: Questions about the oil leak repair process
Post by slavy on 04/11/05 at 06:57:50

It is hard to see on the picture where is the oil comming from. You see the oil dripping from thr lowest point, but it might be comming from some place above and in front or in the side. My best suggestion is to wash the engine nice, wait to dry and leave the bike to work in the place. Watch periodically to see where the oil will show and follow the leak to verify this is it. It is very probable that the head cover leak got bad enough that the oil is comming from the top to the bottom.

Title: Re: Questions about the oil leak repair process
Post by Red_Wine on 04/11/05 at 09:58:09

slavy wrote:

It is very probable that the head cover leak got bad enough that the oil is comming from the top to the bottom.

I agree, my bike also has the pulg cap leak and the bottom looks like that after a couple of days riding...

I'd fix the cap leak first, and then check if there is still oil at the bottom... might just be a one-fix leak....

Take care,

RW

Title: Re: Questions about the oil leak repair process
Post by Reelthing on 04/11/05 at 11:49:19

Spoccie wrote:

I would sure fix the head cover cap first - and watch it awahile - that maybe the wonderful speedometer cable gasket - if you raise the spring up do you see any oil at the base of the cable?

Title: Re: Questions about the oil leak repair process
Post by Greg_650 on 04/13/05 at 05:32:21

The best thing would be to go to a self-car wash and wash the engine.....then ride it around and go home and look again....

You have 3 potential leak spots on that side, not counting the left side cover gasket.

Rubber seal around the nuetral wire on the rear of the engine.

Seal around the clutch actuator lever.

Seal inside the speedo cable (already mentioned)

Title: Re: Questions about the oil leak repair process
Post by Oklahoma_Mike on 05/16/05 at 19:53:47

What is the part # for the NEW plug? 8)

Title: Re: Questions about the oil leak repair process
Post by Reelthing on 05/16/05 at 21:43:50

so far as I can tell it is 11145-41b01

Title: Re: Questions about the oil leak repair process
Post by Savage_Rob on 05/17/05 at 07:08:48

The top center bolt was the only one I couldn't get the torque wrench on. That said, I put it in finger-tight, torqued all the rest and byt that time had a good feel for how tight to estimate that one. It's not perfect, but it seems to have worked so far.

Title: Re: Questions about the oil leak repair process
Post by Setral on 05/19/05 at 08:14:03

My oil leak might be the exact same spot. But when the bike is sitting on the kick stand, the oil drips from the exhaust and when the exhaust gets hot it starts smoking.

Which is why I'm confused if the problem is the area Spoccie is showing, or actually at the exhaust/muffler connection.

Title: Re: Questions about the oil leak repair process
Post by Oklahoma_Mike on 05/19/05 at 15:28:16

Setral wrote:

Mine was doing the same thing oil was coming out of the cap when I was ridding and running down the motor. wind would catch dropplets of oil and send then all over the lower rear half of the bike. 8)

Title: Re: Questions about the oil leak repair process
Post by Greg_650 on 05/20/05 at 06:50:07

You won't be leaking oil from the muffler connection....now oil may be dripping ON the clamp area and then on the floor, but not from the muffler itself.

Did you wash the bike and try to find the leak?

Title: Re: Questions about the oil leak repair process
Post by Setral on 05/20/05 at 08:29:27

I washed all of the bike, except the very base/bottom of the engine because at the time I didn't have the space to do it.

I looked at it closer last night, still not sure where exactly it is starting at.

Title: Re: Questions about the oil leak repair process
Post by Greg_650 on 05/20/05 at 09:39:43

Look at every point of entry on the right side engine case...clutch lever, nuetral wire, speedo cable, filter cover, and the side case gasket.

Personally, since I've had the "plug leak", I can't imagine it leaking so much that it gets down there....if so, it would also be all over your battery box and side covers.

Title: Re: Questions about the oil leak repair process
Post by Oklahoma_Mike on 05/20/05 at 15:03:03

Greg_650 wrote:

Mine was leaking down there but as you suggested it was on the front of the battery box, but not on the side covers it was also slinging over to the muffler clamp. 8)

Title: Re: Questions about the oil leak repair process
Post by Oklahoma_Mike on 05/28/05 at 23:32:26

Thank you Greg and all. With the help of Greg's Tech Thread it went flawlessly and BAM no leaks it allowed me to take a 4 hour trip all over Northern Oklahoma today 250 miles of so here is some pics
http://i5.photobucket.com/albums/y177/diggintaz/Pictures00180.jpg
http://i5.photobucket.com/albums/y177/diggintaz/Pictures0053.jpg
http://i5.photobucket.com/albums/y177/diggintaz/Pictures0050.jpg

And after 250 miles look mom no leaks

http://i5.photobucket.com/albums/y177/diggintaz/Pictures0004.jpg

8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8) 8)

Title: Re: Questions about the oil leak repair process
Post by bobo383 on 05/28/05 at 23:49:44

She was a fast machine
kept her motor clean

Dang - I wish my fast machine kept its motor clean like yours does. Mine is leakin' from the little nut under the exhaust port.

Title: Re: Questions about the oil leak repair process
Post by Greg_650 on 05/29/05 at 06:43:37

Oklahoma_Mike wrote:

You are welcome, but of course we all learn by doing. Now you'll be able to help someone else through it.

Your bike's looking good. The engine is nice and clean.

2 things in your last photo :P

1. You just gotta take a hair dryer to that ugly frame decal.

2. Caught ya...:) Watch out for muffler burns, if you are gonna ride while wearing shorts....those things take forever to heal.

Title: Re: Questions about the oil leak repair process
Post by Oklahoma_Mike on 05/29/05 at 07:38:14

Greg_650 wrote:

I will and I knew the reflection would get me in trouble. hahahaha 8) 8) 8)

Title: Re: Questions about the oil leak repair process
Post by Oklahoma_Mike on 05/29/05 at 07:41:13

bobo383 wrote:

She was a fast machine
kept her motor clean

Dang - I wish my fast machine kept its motor clean like yours does. Mine is leakin' from the little nut under the exhaust port.

Thank you sir. Are you talking about the one head bolt under the plug cap that I just replaced or the acorn nut lower? 8)

Title: Re: Questions about the oil leak repair process
Post by bobo383 on 05/29/05 at 09:22:48

The little acorn nut, visible from the front of the motor, below where the header pipe goes in.

It did leak at the plug/cap, but thanks to Greg650 it don't leak there no more.