Oil dripping from exhaust manifold - 1980 gs550 et

[ukjules]

Issue:
1) Oil dripping from the exhaust manifold. (Cylinder 1 only) See the picture. it is not coming from head gasket i am convinced.
the oil dripping is clean too.
When the exhaust was removed inside near the exhaust valve was dry but typical black deposits.
unscrewing the exhaust manifold bolts lower one was oily and around the gasket.
the exhaust gasket was broken and area was oily ?Spark plug is a bit back but sorting the mixture to solve this (2 1/4 turns out so far and testing)


New base gasket fitted - ok
New head gasket - i am convinced this is fine and no leaks (I am trying to keep quiet here re my athena gasket test previously)
re torqued head and cam cover
leak not coming from cam cover
This only started after the base and head gasket work.
bike runs perfectly - no smoke whatsoever when warm, ticks over perfectly.
When it starts there is always smoke but always has been - the amount has never changed - a small amount of white smoke.
Oil seals done 2000 miles ago.



2) leak from from bottom of stator. This is not related as I though the oil was blowing out and back up
when going along. Ill fix this with a double gasket or a gasket with some gasket sealer on both sides of the gasket.

gs550 oil leak.jpg

[Steve]

I see in your picture that you have a non-stock exhaust system. That, in itself, is not a problem, but there is a possibility that one of the bolts that holds it in place might be just a little bit too long and has punched through the back of the hole, into an oil gallery. If you are not getting any oil dripping on the outside above that spot, that is about the only way you are going to have oil at that location.

.

[ukjules]

The exhaust has been on there with standard bolts to head for before I bought it and
No issues. Possible though I agree.
If so it's head off and aluminium welding .

I'll add another picture as just done a 20m blast on bike and
It is very slowly dripping from that manifold at the bottom, possibly trickling down from the lower exhaust bolt.
This is just above head gasket which is fine - not blowing.

It simply must be as you say though ?
It can't be coming out of exhaust surely ?IMAG1136.jpg

[Steve]

I would think that if it were coming through the exhaust port, it would not be so "clear".

.

[TxGSrider]

Why not remove the bolt and see if oil runs out?

[ukjules]

I have removed the downpipe and both bolts.
Nothing comes out when cold !
The lower bolt was oily. ( I did this before was informed that this hoping the head could even happen ?)

It's just i have never heard of a exhaust bolt pushing into the head ?
But what else can it be ?
If we assume that this is the case how could it be fixed ?
Temporarily and permanently ?

I can in the end i can remove head and blast with parts cleaner spray to see
If there is a way for oil to come out. But I don't want to do that yet.
Again another 20 mile run and it runs fine.
Re torquing stator cover has made that better too.

[TxGSrider]

Ok, then maybe try this (I'm sure someone on the site will think this is a bad idea, but...), remove the bolt, clean it, and apply some high temperature sealer on the threads and the base of the head. Tighten it back down, let it dry, and see if the leak stops. You could just use it for a diagnostic tool and not a permanent fix to see if that is indeed the problem. If it turns out to be a crack or hole in there somewhere, I don't think Id ride it for long like that as those types of things tend to get bigger after a few heat cycles.

[ukjules]

Got some gasket sealer rtw, high temp copper stuff coming.
Will try that. (This will sort the stator cover too when I do that )
As you say we are in evaluation mode at present so I agree a good plan.

(I am sure it might get worse but it has remained the same for 300 miles
Now. Point noted though.)
The only issue is the sun is shining and hard not to ride it for such a small leak.
Will report ...

[ukjules]

I think i have sorted where the oil is coming from and why it looks so clean !

I took cy 1 and 2 exhausts off, cleaned area and checked bolt holes and i could not
see any way oil can come a) out of the exhaust b)out of bolt holes.
c) head gasket not leaking

I ran the bike a bit with no exhausts in cy 1 and 2 - not much happened but no oil coming our of bolt holes.
totally dry.

The issue i think:
There is a mild oil leak on the cam cover it leaks a bit on the LH side internally.
It can and does drip down to near the plug, plugs. (clean oil)

Now this clean oil can escape to the exact location through small vent holes near the plugs.
This absolutely has to be the reason.

I only write this as on these forums it is def good to have the full story - might help someone in the future to
diagnose quicker.

But I can now ride knowing it is not a critical issue just a normal oil leak....
thanks for help though, as always.

[TxGSrider]

I think i have sorted where the oil is coming from and why it looks so clean !

I took cy 1 and 2 exhausts off, cleaned area and checked bolt holes and i could not
see any way oil can come a) out of the exhaust b)out of bolt holes.
c) head gasket not leaking

I ran the bike a bit with no exhausts in cy 1 and 2 - not much happened but no oil coming our of bolt holes.
totally dry.

The issue i think:
There is a mild oil leak on the cam cover it leaks a bit on the LH side internally.
It can and does drip down to near the plug, plugs. (clean oil)

Now this clean oil can escape to the exact location through small vent holes near the plugs.
This absolutely has to be the reason.

I only write this as on these forums it is def good to have the full story - might help someone in the future to
diagnose quicker.

But I can now ride knowing it is not a critical issue just a normal oil leak....
thanks for help though, as always.

I hope you found it...and thank you for letting us know. I hate never finding out how threads like this end. lol

[ukjules]

99% sure so assume this is the issue.

Quick question - have you ever heard of putting on a double gasket on a old stator cover leak ?
(was told this by an old timer .........)
(assume the surfaces are cleaned to perfection, new good gasket fitted and it still leaks.
probably from a previous owners butchery on the surfaces) Leaks very slowly though so could almost ignore it.
Torqued all bolts etc fine.
Would you try a double gasket ?
and if that fails
new gasket with "COPPER RTV SILICONE INSTANT GASKET MAKER HIGH TEMP 700°F OIL RESISTANT " on both surfaces of gasket ?
or use the instant gasket with proper gasket first ?

just be interested in how others fix these annoying little leaks.

[TxGSrider]

I really don't see how it could leak of both surfaces are clean and flat and torqued down tight. However, theres some amazing sealer called "The Right Stuff" https://www.permatex.com/our-brands/the-right-stuff/ that I have used in places that wasn't so flat or smooth, and it has always sealed and held on old cars and Quads. The stuff if fantastic.

[yank]

I would not put double gaskets on any surface. Even gaskets thicker than stock could cause problems.

[ukjules]

Ok points taken.
Think I spoke too soon on exhaust oil leak issue.
I don't think I will ever know where or how it is getting to where it is ?
It is impossible to me how it is happening unless it is coming from
Inside the cylinder.
I have many bikes from the 80's and not one is oil leak free.
I totally despair.

I can fix the stator leak however easily with some gasket sealer.
The other exhaust one , Ill live with it for a bit as the bike still runs like a dream.

[ukjules]

Update:
New stator gasket and dowel.
New oem head gasket
New cam cover gasket
New chain tension gasket.

All gaskets put on with a coating of wellseal on both sides
Of gasket.
Torqued all bolts.

Result is no leaks whatsoever.
Will 're torque head later in week.

Where the oil leak came from I have no idea.
I think however it could have come from can chain tensioner.
I would not have dreamed it was possible but another thread on here had similar issue.

The bottoms line is my stator cover leak has been sorted
With wellseal. A chap from Kawasaki site told me of this
As never heard of it.

All good now though .