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Message started by renegade1 on 08/09/12 at 12:25:39

Title: plug/cap leak?????
Post by renegade1 on 08/09/12 at 12:25:39

Just noticed quite a bit of oil coming outta the top of the motor... would this be the result of this " plug " problem?? is there a walk through on how to fix it if is the problem.

Title: Re: plug/cap leak?????
Post by CalisOsin on 08/09/12 at 12:40:51

I think we would need more details and a picture wouldn't hurt, but it's possible. Have you taken a look at this thread http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1099227295 to see if it's leaking from the same place?

Title: Re: plug/cap leak?????
Post by renegade1 on 08/09/12 at 23:10:12

camera is messed up right now so i cant do that sadly enough but its pooling on top of the cover. and yes i have seen that post and just could not figure out if thats what it is :P and its spraying up i have to ride 30 minutes to work and back everyday. thought it might be my crank case breather tube disconnected but it was not that. causing a lot of blow back also...

Title: Re: plug/cap leak?????
Post by renegade1 on 08/10/12 at 11:38:54

cant get the new cap untill after the weekend... should i still dig into it and see whats going on or just put my tank back on and hook everything up and call it a day untill i can get that plug/ or take it all appart and re-seal that plug?? i dont know if that would work

Title: Re: plug/cap leak?????
Post by CalisOsin on 08/10/12 at 11:42:28

If it's pooling then it sounds like you have a pretty big leak. I wouldn't ride it that way, you risk some major damage. Blow back is pretty consistent with that leak though. You might try cleaning it all off, buttoning it back up, refilling the oil, and going for a short ride. It might help you determine where the leak is.

Title: Re: plug/cap leak?????
Post by renegade1 on 08/12/12 at 01:31:54

i keep hearing that i have to do something with "tdc" before i open up the cover haha but i have no idea what that means or how to do it, can any of you fine folks enlighten me on this?

Title: Re: plug/cap leak?????
Post by J C Stokes on 08/12/12 at 01:36:47

TDC means TOP DEAD CENTRE there are many posts on how to find it. You will need to remove the large slotted round thing on the left hand cover and align two marks inside. The rest I will leave to the experts.

Title: Re: plug/cap leak?????
Post by CalisOsin on 08/12/12 at 07:50:27

Maybe someone can correct me here, but if you're just fixing the plug leak there is no need to worry about tdc.

Title: Re: plug/cap leak?????
Post by renegade1 on 08/12/12 at 15:27:09

just heard in the tech section about people didnt take that into consideration while doing it but they should have i dont really understand haha under plug/cap leak fix i believe

Title: Re: plug/cap leak?????
Post by Dave on 08/12/12 at 18:27:06

0F2D20253F033F25224C0 wrote:

Maybe someone can correct me here, but if you're just fixing the plug leak there is no need to worry about tdc.

If the engine is at a point where the cam is pushing on a valve and has it open - the valve spring will be putting a lot of tension on the cam. The cylinder head cover is the top bearing for the cam - so if the valve spring is pushing on the cam - the cam will try to come out of the bottom bearing halves in the cylinder head when you take of the cover to fix the plug leak. It is best to get the engine at TDC so that the cam is not pushing on the valves.

Title: Re: plug/cap leak?????
Post by renegade1 on 08/13/12 at 10:03:57

so do you do this before you actually take off the cover?

Title: Re: plug/cap leak?????
Post by Dave on 08/13/12 at 10:09:31

26313A313335303165540 wrote:

so do you do this before you actually take off the cover?

You don't have to find TDC before you take off the front or back covers with the two screws holding them on. Those covers are only the access points for valve adjustments. You have to find TDC before you take off the large Cylinder head cover that those little covers attach to.

Title: Re: plug/cap leak?????
Post by renegade1 on 08/13/12 at 12:16:40

guess i gotta look in the tech section to figure that whole process out hey... just dont understand how you can see where the marks line up

Title: Re: plug/cap leak?????
Post by youzguyz on 08/13/12 at 12:28:28

455259525056535206370 wrote:

guess i gotta look in the tech section to figure that whole process out hey... just dont understand how you can see where the marks line up

The place with the marks is under the round cover (with a slot in it) on the left side of the engine, at the end of the crankshaft.
You unscrew that cover, then you can see the end of the crankshaft, and it has a mark on it. The engine case has a mark as well. When those two line up, you are at TDC.
BUT, you need to be sure you are at TDC on the compression stroke.
That is why you open the valve covers, so you can see which valves are open or closed. Both valves closed, and at TDC, That is where you want to be.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1278347767

Title: Re: plug/cap leak?????
Post by Dutchmen on 08/13/12 at 12:34:46

Don't you want to adjust the valves after this repair?

Title: Re: plug/cap leak?????
Post by verslagen1 on 08/13/12 at 12:36:49

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1325991352

Title: Re: plug/cap leak?????
Post by renegade1 on 08/13/12 at 15:03:35

i dont have a proper measuring tool to gauge the gap of the valves, should this be done since im in there anyways?
and is 650 temp silicone the only one that can be used? will i run into trouble with a 600 rating?

Title: Re: plug/cap leak?????
Post by CalisOsin on 08/13/12 at 18:09:48

$5-$10 at auto zone http://www.autozone.com/autozone/accessories/Tools-Garage-and-Equipment/Feeler-Gauge/_/N-265p

Title: Re: plug/cap leak?????
Post by Digger on 08/13/12 at 21:06:35

43545F545650555400310 wrote:

Title: Re: plug/cap leak?????
Post by renegade1 on 08/13/12 at 22:56:34

thank you for the good luck wish, im going to be tackling this very soon just waiting for the plug to get in to the shop so i can go grab it... i got some copper permatex rated to 700 for $8.00 at walmart (man i love walmart) and looking into one more question with my lucas supplier about the wet clutch with the fluid they would supply, or i might just go with the jaso-ma rated rotella t 15w40.

Title: Re: plug/cap leak?????
Post by renegade1 on 08/20/12 at 21:14:12

New problem YAHHHHHH >:( Putting everything back together all went nice UNTILL i went to put the petcock back on first bolt went in nice and smooth but then it came to the 2nd one and it was tightening up and then just SNAP broke in half inside the tank... WOO HOO so now i have no idea what to do!!

Title: Re: plug/cap leak?????
Post by SaVaGeEaRL on 08/21/12 at 07:50:13

59747A7A786F1D0 wrote:

[quote author=43545F545650555400310 link=1344540340/15#16 date=1344895415]i dont have a proper measuring tool to gauge the gap of the valves, should this be done since im in there anyways?
and is 650 temp silicone the only one that can be used? will i run into trouble with a 600 rating?

Title: Re: plug/cap leak?????
Post by youzguyz on 08/21/12 at 08:19:55

544E494C4B4A5C55390 wrote:

[quote author=59747A7A786F1D0 link=1344540340/15#18 date=1344917195][quote author=43545F545650555400310 link=1344540340/15#16 date=1344895415]i dont have a proper measuring tool to gauge the gap of the valves, should this be done since im in there anyways?
and is 650 temp silicone the only one that can be used? will i run into trouble with a 600 rating?

ren,

If you pull the head cover (which is a required operation if you are replacing the rubber plug that you think is leaking), then you really should inspect the valve clearances after you get said head cover back on. Reason: the act of removing and then replacing said head cover actually messes with the valve clearances....it's just the way the top end is designed.

Good luck....we're here for you!
[/quote]

please explain how removing the head cover has any effect on valve clearance.[/quote]

The valves sit in the top of the head. The rocker arms sit in the head cover.
You open that joint when you replace the plug cap. You put it back together with sealant between the surfaces. If the sealant thickness is not EXACTLY the same as was when you took it apart, the valve clearance will be off.
Hope that helps.

Title: Re: plug/cap leak?????
Post by SaVaGeEaRL on 08/21/12 at 09:12:28

you are incorrect. the headcover in no way effects the valve clearance. the rocker arms are in no way attached to the head cover. the head cover only covers everything.as a matter of fact, the easiest way to adjust the valves is when the headcover is off, cuz its so much easier to get to the valves if all you have are the long flimsy feeler gauges.

Title: Re: plug/cap leak?????
Post by Dave on 08/21/12 at 09:28:45

706A6D686F6E78711D0 wrote:

Wow! You owe youzguys an apology.....he is absolutely correct.

Here is a photo of the headcover that must be removed to get to the leaky plug. You may be thinking about the small access caps that attach to the front and and rear of the head cover.....that allow you to access the rockers for the valve adjustments. You will note in the photo of the headcover....it has the rockers arms attached.

Title: Re: plug/cap leak?????
Post by Dave on 08/21/12 at 09:37:38

One more picture borrowed from the Technical Section. You can see the red sealant on the mating surface between the cylinder head and the head cover....this sealant will be removed and replaced.....and this may affect the valve clearance if the sealant thickness is not exactly the same before/after.

You can go to this link to see the process.

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1099227295

Title: Re: plug/cap leak?????
Post by SaVaGeEaRL on 08/21/12 at 09:47:57

I must be losing my mind cuz I sure dont remember it being like that when I changed mine and could have sworn i noticed how easy the valves would be to adjust while it was off. owell my mistake.