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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Well, I reached the end of the line with my S40 /cgi-bin/YaBB.pl?num=1665610530 Message started by och on 10/12/22 at 14:35:30 |
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Title: Well, I reached the end of the line with my S40 Post by och on 10/12/22 at 14:35:30 For the last several months I've been battling a major oil leak from the stator cover. It started out pretty minor, but got progressively worse, where it became major. Looks like it is leaking from the stator plug. At first I tried to fix it myself, by replacing the gasket - no success. My mechanic tried 4 times, two more gaskets, no success. He refused to try further. I've been fixing it myself for the last week. I took the whole thing apart, removed the cover from the bike completely, which requires removal of the kickstand, the seat, the battery box, etc. I cleaning it very thorough, applied permatex ultra black into the slot where the plug goes, installed the plug and set the cover under a 50lb weight to press the plug in. Waited 24 hours, applied permatex from the inside and outside around the plug and the wires, sealing every potential source for oil penetration. Then i cleaned everything again, cleaned the engine case, applied a bead of permatex all around and installed the cover. As per Permatex instructions I tightened the bolts by hands, waited an hour and tightened them to spec. Then I waited 24 hours to let permatex cure completely before filling with oil. This whole process with the 24 hour waiting periods took me a better part of the week. I just assembled everything today, filled with oil, went for a ride, and the god darn thing is dripping oil again. I have no more time, will, or resourced to go further. I can't keep riding it with the leak either - I do not like oil all over my driveway, and its also a safety issue as the air pushes the oil over the rear tire when riding. A darn shame, I put a bunch of $ and effort into it over the years, and with just 6k miles its no longer repair worthy. |
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Title: Re: Well, I reached the end of the line with my S4 Post by Surviving Philadelphia on 10/12/22 at 15:05:40 Are you certain the cover/plug is the source of the leak? If so maybe pick up a used replacement? It looks like Ebay has quite a few for not much. https://www.ebay.com/itm/195214093473?chn=ps&norover=1&mkevt=1&mkrid=711-117182-37290-0&mkcid=2&mkscid=101&itemid=195214093473&targetid=1645685073808&device=c&mktype=&googleloc=9007299&poi=&campaignid=16730423415&mkgroupid=135815925780&rlsatarget=pla-1645685073808&abcId=9300841&merchantid=119306966&gclid=EAIaIQobChMI5fLDsdnb-gIVGbjICh0logJpEAQYAiABEgKVcPD_BwE |
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Title: Re: Well, I reached the end of the line with my S4 Post by Moarpower on 10/12/22 at 18:36:30 This sounds crazy and frustraiting. I literally have had mine off of my 87 3 times in the last month dealing with starter gears and haven't even changed the gasket until today. The whole time I've had no leaks. Are you referring to the rubber grommet attached to the stator wiring? If so, there is a chance that it is just cracked and no longer useable. you'd probably be fine just replacing the stator itself with a good one. Sorry that you are having a hard time mate. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/12/22 at 23:02:26 It really doesnt look cracked, but even if it is, I applied so much gasket maker to the back of it, it should be sealed. What kinda issue are you having with the starter gears? |
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Title: Re: Well, I reached the end of the line with my S4 Post by Moarpower on 10/12/22 at 23:15:27 They all broke ;D so filling a flushing and cleaning out the case a few times before I am willing to ride it again. |
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Title: Re: Well, I reached the end of the line with my S4 Post by DragBikeMike on 10/13/22 at 12:05:00 There is a drain hole in your left-side engine case to allow liquid to drain out of the cavity directly below your starter. There is also a pressurized oil passage that runs directly behind the starter. That oil passage utilizes an o-ring at the case joint. The picture shows the drain hole circled in yellow, and the o-ring joint circled in green. |
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Title: Re: Well, I reached the end of the line with my S4 Post by DragBikeMike on 10/13/22 at 12:08:08 The drain hole in that cavity will dump oil directly on the area where you have a problem. The starter has an o-ring to seal it to the case. That o-ring is situated directly above the cavity drain hole. If it is damaged it will leak oil into the cavity and drain hole. Remove the starter and check the cavity and o-ring joints for leaks. |
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Title: Re: Well, I reached the end of the line with my S4 Post by DragBikeMike on 10/13/22 at 12:12:06 Have you checked your engine breather to make sure it's not obstructed? It's the large hose on the top right-hand side of your cylinder head cover. Make sure the vent connection on the head is clear (no obstructions), same for the hose, and same for the nipple on your airbox where the hose vents to. |
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Title: Re: Well, I reached the end of the line with my S4 Post by DragBikeMike on 10/13/22 at 12:12:41 Dave found one like this not too long ago. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/13/22 at 12:36:39 Thank you Mike, that is a lot of good info. For now I dont want to take everything apart, this thing drained all the energy out of me. Maybe I'll get to it again some day. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/13/22 at 13:33:01 That drain hole in yellow seems interesting, I definitely need to check it. |
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Title: Re: Well, I reached the end of the line with my S4 Post by Surviving Philadelphia on 10/13/22 at 14:37:36 Mike, out of curiosity, in your picture what exactly is that obstructing the engine breather? Never seen anything like it. |
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Title: Re: Well, I reached the end of the line with my S4 Post by DragBikeMike on 10/14/22 at 17:35:38 It looks like the screen assembly normally installed inside the head cover. Possibly someone forgot to install it and tried to backfit (literally). Dave worked on it so best to inquire with him. He might have more info. If the vent is plugged, capped, or otherwise obstructed, it might cause all sorts of leaks in locations such as those described in this post. Easy enough to check. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/15/22 at 13:31:00 Mike, thank you so much. Took out the two bolts that hold the starter, and it came out with no effort. The o-ring on the starter doesn't seal at all, so obviously the oil is leaking through the starter o-ring and weeping out of the weep hole on the stator cover. All this time, money, and energy I've spent fixing something that wasn't broken. http://https://i.imgur.com/DnFjNLS.jpg http://https://i.imgur.com/yte5Tsb.jpg http://https://i.imgur.com/Ve8RIRO.jpg My starter was replaced by a local shop about 1.5 years ago. I found an old thread where it turns out Suzuki sells a wrong size o-ring for out starters. I understand the shop did not know that, but the technician working on it should've known something isn't right when installing the new starter and not feeling any effort or feedback when the o-ring snaps in. This is the old thread. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1183949991/0 Going to research it, and get a new o-ring and hopefully solve this issue for good. On a side note, I see the starter has only one wire going to it, and if I had to guess it seems to be the ground wire since it attached directly to the housing, so it can't be the hot wire. How the hell does the starter work without a positive wire? |
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Title: Re: Well, I reached the end of the line with my S4 Post by justin_o_guy2 on 10/15/22 at 13:34:20 The wire to the starter is the hot wire. It grounds through the engine case,the big wire to the rear on the right side of the engine is ground. Trouble ensues when it gets corroded. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/15/22 at 15:10:24 3C2325223F3809390931232F64560 wrote:
Yep, figured this out, there is an insulation spacer towards the end of the wire connection. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/15/22 at 15:11:21 Just ordered a few size o-rings from McMaster, will update this thread once I find the size that works. https://www.mcmaster.com/o-rings/system-of-measurement~metric/ |
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Title: Re: Well, I reached the end of the line with my S4 Post by justin_o_guy2 on 10/15/22 at 17:15:36 Clean up any marks and dings if there are any. Lightly grease it. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/18/22 at 18:28:57 Just installed a 35mm ID x 3.5mm thick x 42mm OD o-ring. Fit very snug, had to tap the starter in with a hammer, I'm sure it won't let any oil through. Will ride the bike in the next few days and update this. This is McMaster part number 1302N604. They are sold in packs of 25 pieces, so if anyone runs into the same trouble, let me know, I'll mail you an o-ring. I have 24 pieces left. ;D |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/20/22 at 11:10:47 Mike, I dont even know how to thank you enough. For several months I've been battling this darn leak, I spent over $1000 in parts and labor, and endless hours of my time... All this effort to fix what wasn't broken. I was already considering either trashing the bike, or getting a whole new motor, the former option being heartbreaking and the later being wallet breaking. All this just to see your post, and one o-ring and three easy to access bolts later the leak is gone. Ten minutes of work at most, and everything is bone dry. Rode it today for a few hours, came back home - everything is bone dry, no dripping. I am a bit disappointed in the mechanic that replaced my starter, he should've known better when he didn't feel any resistance from the o-ring, but it is what it is. My baby is bleeding no more, and I'm just happy to ride it again! http://https://i.imgur.com/fnmjuST.jpg |
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Title: Re: Well, I reached the end of the line with my S4 Post by TheSneeze on 10/20/22 at 12:32:47 Glad to hear you outlasted the problem! I am always a bit disappointed when I hear people give up on their bikes. But then again, not everyone is up to the wrenching and tinkering to keep them running at their best. |
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Title: Re: Well, I reached the end of the line with my S4 Post by justin_o_guy2 on 10/20/22 at 15:55:42 I hope nobody goes through that much Hell to locate a leak, ever again. Sure glad you figured it out Before you did something drastic. Now, is there anything you can say for the next guy? If you had to figure it out again, is there something you could do that would lead your eyes up higher? Find it Up There, where it came from, instead of seeing it drip off the motor and believe it was leaking there? |
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Title: Re: Well, I reached the end of the line with my S4 Post by DragBikeMike on 10/20/22 at 17:55:42 Gratifying to hear you were successful. Very glad you got it fixed. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/20/22 at 18:25:37 495650574A4D7C4C7C44565A11230 wrote:
I guess sometimes you gotta think outside the box, but if it wasnt for Mike's post, I'd probably keep fighting with the cover and never discover the correct problem. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/20/22 at 18:26:32 73757A06040307370 wrote:
Yep, thank you so much. Hopefully someday I can return the favor by helping others. |
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Title: Re: Well, I reached the end of the line with my S4 Post by ohiomoto on 10/24/22 at 19:55:42 So it's not the end of the line after all. More like the brink. #savedByDragBikeMike |
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Title: Re: Well, I reached the end of the line with my S4 Post by LANCER on 10/25/22 at 07:03:15 0F08090F0D0F140F600 wrote:
[ch128077] [ch128171] [ch128165] |
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Title: Re: Well, I reached the end of the line with my S4 Post by TheSneeze on 10/25/22 at 10:54:54 I got the starter o-rings, OCH. Thanks a bunch! |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/25/22 at 14:00:55 716E4B4C464F435049220 wrote:
Great, hope one of them works on your bike! The medium size is the one that worked for me. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 10/25/22 at 14:03:04 2423222426243F244B0 wrote:
Not the end at all, this bike got another 100k in it now, lol. Just gotta make sure to do Versy cam chain tensioner before its too late! |
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Title: Re: Well, I reached the end of the line with my S4 Post by iceman7376 on 05/08/23 at 07:48:14 272B20480 wrote:
Have any O-Rings left, seems my wife's bike has this leak. |
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Title: Re: Well, I reached the end of the line with my S4 Post by och on 05/08/23 at 16:52:36 Yeah, pm me your address, ill put them in the mail. |
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