SuzukiSavage.com - clutch cover gasket?

weracerc Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 594 Greensboro, NC Gender:	clutch cover gasket? 08/11/11 at 09:37:32 OK i got my new clutch cover gasket in today from cheapcycleparts.com - it has sealant already applied to the top on both sides - is there any need to add sealant to the rest of the gasket on either side or both?
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youzguyz

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Re: clutch cover gasket?
Reply #1 - 08/11/11 at 10:50:42

In theory, it is "good to go" as is.
Some don't use a gasket at all, just gray sealant.
Some also put chapstick on one side so it comes apart easier on the next opening, and they can re-use the gasket.
Some use a thin coat of sealant all around both sides of the gasket just to be sure it doesn't leak.

My experience (limited, as I don't open it up often).
The gasket gets too brittle to re-use anyway, but the chapstick should make surface cleanup easier.
Do the light coat of grey sealant all the way around as well. VERY light coat.
The '00 just got that treatment, and it doesn't leak.

The '02 will be getting a gasket that did NOT come with the sealant already applied to those areas, so I will be putting a tiny bit extra in those areas.

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weracerc Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 594 Greensboro, NC Gender:	Re: clutch cover gasket? Reply #2 - 08/11/11 at 11:04:30 I have a tube of ultra copper i used on the head cover - will that work or does it have to be the grey?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: clutch cover gasket? Reply #3 - 08/11/11 at 11:36:55 no need to add anything, good to go. However, a light application of oil or wax (chapstick) to one side will make reinspection at a later date possible.
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Sunchasers Full Member Offline SuzukiSavage.com Rocks the Rockies! Posts: 232 Northern Colorado Gender:	Re: clutch cover gasket? Reply #4 - 08/11/11 at 12:56:47 I used the exact same gasket this winter without any additional sealant... haven't had any problems with oil leaks so far this summer.
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weracerc

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Greensboro, NC
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Re: clutch cover gasket & re-assembly?
Reply #5 - 08/12/11 at 05:23:44

ok i did the verslavey about a 2 on the 1-10 scale just because i had to borrow snap ring plyers

re-installed the cover - gooped the gasket both sides all the way around with grey

got it all buttoned up to realize the clutch lever was not horizontal - would not come up either - had to tear the cover off clean all the goo and re-goo the case & cover and re-install the cover making sure to hold the clutch lever horizontal while installing the cover.....cant remember if that was addressed in the verslavey thread or not......

letting the goo cure 24hours and will fill the bike with oil tonight - test ride tomorrow.

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Oldfeller--FSO Serious Thumper ModSquad Offline Hobby is now "concentrated neuropany" Posts: 12673 Fayetteville, NC Gender:	Re: clutch cover gasket? Reply #6 - 08/12/11 at 10:02:57 You do realize if you grip the upper and lower surface of the clutch lever with a large crescent wrench that you can move the lever "up" until you have enough room to flip the U notch into the upright position without taking everything apart, now don't you?
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weracerc Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 594 Greensboro, NC Gender:	Re: clutch cover gasket? Reply #7 - 08/12/11 at 10:13:11 i did not know that...you dont know what you dont know - now i know.....the clutch lever arm felt very tight as if it would not be moved up to the level position without breaking or damaging something.....just glad the goo was still pliable and easy to remove and the gasket was not harmed......
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ralfyguy

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Re: clutch cover gasket?
Reply #8 - 08/12/11 at 10:32:25

weracerc wrote on 08/11/11 at 09:37:32:

OK i got my new clutch cover gasket in today from cheapcycleparts.com - it has sealant already applied to the top on both sides - is there any need to add sealant to the rest of the gasket on either side or both?

http://p1.bikepics.com/2011/08/11/bikepics-2255033-800.jpg

http://p1.bikepics.com/2011/08/11/bikepics-2255031-800.jpg

I personally had troubles with the same leak several times in a row. I went through three gaskets and it always started leaking around the bolt hole all the way on the right in the top picture/all the way on the left on the bottom picture after about 50-100 miles. On the bottom picture you can see that the additional sealant doesn't go around the hole like is does on the opposite side. For some reason on my bike I have troubles with that. The final time I replaced the gasket I put some sealant all around the whole on the back side, and it is now fine ever since. There was no evident damage to the surfaces in that area, so it still baffles me why I had to do that. I also don't know why the same areas where done differently with additional sealant on both sides. Seems to make no sense to me.

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ralfyguy

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Re: clutch cover gasket?
Reply #9 - 08/12/11 at 10:40:42

youzguyz wrote on 08/11/11 at 10:50:42:

In theory, it is "good to go" as is.
Some don't use a gasket at all, just gray sealant.
Some also put chapstick on one side so it comes apart easier on the next opening, and they can re-use the gasket.
Some use a thin coat of sealant all around both sides of the gasket just to be sure it doesn't leak.

My experience (limited, as I don't open it up often).
The gasket gets too brittle to re-use anyway, but the chapstick should make surface cleanup easier.
Do the light coat of grey sealant all the way around as well. VERY light coat.
The '00 just got that treatment, and it doesn't leak.

The '02 will be getting a gasket that did NOT come with the sealant already applied to those areas, so I will be putting a tiny bit extra in those areas.

I wonder if the ones that only use sealant have issues with the clutch engagement, since the gasket adds another 1mm to the distance from the clutch lever cam to the clutch pin.

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