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    #1

    Ugh dang it, a leak

    Crap, found a leak under my clutch cover this morning in the shop. I had installed my new clutch springs and cleaned the gasket surfaces and installed a new factory gasket as well....grrr. Haven't even started it yet
    sigpicMrBill Been a GSR member on and off since April 2002
    1980 GS 750E Bought new in Feb of 1980
    2015 CAN AM RTS


    Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.
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    #2
    Originally posted by mrbill5491 View Post
    Crap, found a leak under my clutch cover this morning in the shop. I had installed my new clutch springs and cleaned the gasket surfaces and installed a new factory gasket as well....grrr. Haven't even started it yet
    The gasket may of slipped off during installation. I use a little silicone (a see through film) on the engine case and put the gasket on the dowels and let it sit for a few minutes.
    1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
    1985 GS1150ES stock with 85 Red E bodywork.

    Comment

      #3
      Originally posted by chef1366 View Post
      The gasket may of slipped off during installation. I use a little silicone (a see through film) on the engine case and put the gasket on the dowels and let it sit for a few minutes.
      Nope gasket didn't slip off. It was on the dowels plus I had a bolt through that part so it wouldn't slip. It is right under the sight glass between the two bolts. One little bitty spot.
      sigpicMrBill Been a GSR member on and off since April 2002
      1980 GS 750E Bought new in Feb of 1980
      2015 CAN AM RTS


      Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

      Comment

        #4
        Originally posted by mrbill5491 View Post
        Nope gasket didn't slip off. It was on the dowels plus I had a bolt through that part so it wouldn't slip. It is right under the sight glass between the two bolts. One little bitty spot.
        You may have some slight warpage. Try a little silicone. It won't hurt if used properly.
        1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
        1985 GS1150ES stock with 85 Red E bodywork.

        Comment

          #5
          Originally posted by chef1366 View Post
          You may have some slight warpage. Try a little silicone. It won't hurt if used properly.
          Now that could be. Thing is I don't want to break the seal on it again. It took a few trys on and off to get the clutch lever set right.
          sigpicMrBill Been a GSR member on and off since April 2002
          1980 GS 750E Bought new in Feb of 1980
          2015 CAN AM RTS


          Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

          Comment

            #6
            Just get the splines to mesh on the inside of the clutch and move the acuator lever to the right spot.
            1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
            1985 GS1150ES stock with 85 Red E bodywork.

            Comment

              #7
              Originally posted by chef1366 View Post
              Just get the splines to mesh on the inside of the clutch and move the acuator lever to the right spot.
              Did that, it was either too far in or too far out when I tried to align the lever. Had to get the splines just right to able to align lever in the right spot. I've done this a few times before.
              Last edited by mrbill5491; 11-16-2012, 03:01 PM.
              sigpicMrBill Been a GSR member on and off since April 2002
              1980 GS 750E Bought new in Feb of 1980
              2015 CAN AM RTS


              Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

              Comment

                #8
                Originally posted by old_skool
                That may be why it's leaking, the gasket is probably crushed and has a memory now of it being torqued, you may have to re-torque it slitghtly higher, or like he suggested, add some silicone to the mating surface, also, you shouldn't have to remove it to adjust your clutch, I back off the clucth adjustment and count my turns, remove the clevis, after I install the case cover, I twist the clutch shaft fully counter clockwise, re-install the clevis, and re-adjust back the same number of turns, and almost always right back where I had it, if not super close only needing minor adjustment.
                Gasket was never torque, just snug down enough to check the action of the clutch springs and I used the old gasket for that. Once I checked the springs, the new gasket went on, then aligned the lever in the right position, then torqued the cover and gasket to specs. I'm thinking a dried out gasket or even not thick enough. I got it off ebay and it wasn't sealed. Didn't look like the old gasket either, the one I took off I know was a Suzuki part, it was a tan color where this new was gray in color.
                sigpicMrBill Been a GSR member on and off since April 2002
                1980 GS 750E Bought new in Feb of 1980
                2015 CAN AM RTS


                Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

                Comment

                  #9
                  Take the lever off its splines and put it in the correct position.
                  1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
                  1985 GS1150ES stock with 85 Red E bodywork.

                  Comment

                    #10
                    Originally posted by chef1366 View Post
                    Take the lever off its splines and put it in the correct position.
                    IT is in the correct position.
                    sigpicMrBill Been a GSR member on and off since April 2002
                    1980 GS 750E Bought new in Feb of 1980
                    2015 CAN AM RTS


                    Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

                    Comment

                      #11
                      Originally posted by mrbill5491 View Post
                      IT is in the correct position.
                      What I am trying to say is you don't need to get the lever in the correct position while mating the inside splines. Just take it off after sealing the gasket and put it in the correct position. It's a pita to get it in the perfect position.
                      1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
                      1985 GS1150ES stock with 85 Red E bodywork.

                      Comment

                        #12
                        Originally posted by chef1366 View Post
                        What I am trying to say is you don't need to get the lever in the correct position while mating the inside splines. Just take it off after sealing the gasket and put it in the correct position. It's a pita to get it in the perfect position.
                        ...........
                        sigpicMrBill Been a GSR member on and off since April 2002
                        1980 GS 750E Bought new in Feb of 1980
                        2015 CAN AM RTS


                        Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

                        Comment

                          #13
                          Think I found the cause of the leak, Took the clutch case back off and measured the thickness of the new gasket and compared it to the other gasket, The new gasket was a bit thinner. So, with that, Friday gonna order a new OEM gasket among some other stuff from Boulevard Suzuki sale.
                          sigpicMrBill Been a GSR member on and off since April 2002
                          1980 GS 750E Bought new in Feb of 1980
                          2015 CAN AM RTS


                          Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

                          Comment

                            #14
                            Since I installed the new clutch cover gasket, leak is fixed. No seeping or anything. I did go back and look over the stock gasket and the one I ordered off ebay. The new stock gasket was flexible and soft to the touch, where as the one I took off (from ebay) was hard and barely flexible. The ebay one I bought was cut from a computerized gasket cutter and used a gray type gasket material. Could have been old and or dried out since it wasn't sealed when I got it. Anyways its all good now. Guess that tells ya something about stock gaskets. Oh yeah did send a note to the ebay guy I bought the gasket from. Go figure no reply.
                            sigpicMrBill Been a GSR member on and off since April 2002
                            1980 GS 750E Bought new in Feb of 1980
                            2015 CAN AM RTS


                            Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

                            Comment

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