slight oil leak

[ddaniels]

Well, I just got my engine covers back from being very nicely polished by Steve. They look great! Thanks Steve. After putting them back on, new oil and filter, I fired it up and there is a bit of a leak right at the top of the clutch cover next to where the clutch cable connects. Question is, do I remove the cover and put on some black gasket sealer, or is there something else I should try? I hope I don't have to get another gasket. It's only been on a couple days. Thanks!

[chuck hahn]

A little RTV or Threebond 1184 wont hurt anything....but be mindfull the gasket has been compressed already so there may well be a chance it will leak somewhere else. Slight risk but still a risk. If you take the cover off recheck that all the old gasket material is off the cases and the rim of the cover....this may well be the culprit.

[Brendan W]

Clutch covers generally have a mixture of screw lengths. 65 , 25 & 20 for example. If a 25 finds its way into a 20 position it can bottom out by just enough to allow a leak but not enough to notice. Replacement capscrews often are too long as well.
Iirc the 850 set up has 2x 65 at the front, 4x 20 at the back and 2x 25 top and bottom.

[bwringer]

You shouldn't need a new gasket. I've re-used a GS clutch cover gasket many times while experimenting with springs.

Just put the bike on the kickstand and you won't lose any oil.

Take it off and the explanation should become obvious. Mixed-up bolt lengths are one common possibility, so you should be able to see if there's an area where the gasket isn't compressed. Any hidden damage to the gasket or the cover should be visible as well.

I've also seen issues (leaking, binding the shifter shaft) caused by very thin aftermarket gaskets. The correct OEM gaskets are fairly thick and resilient.

Don't overlook the seal for the clutch lever shaft and make sure the o-ring around the oil filler cap is present and in good shape. If the mystery continues, you may need to clean it off, spray with foot powder, and watch where the leak emerges.

[ddaniels]

Thanks guys. I took the cover back off, put on some black gasket sealer and put it back on...same gasket. No leaky now. I really hate using that goopy stuff but sometimes it helps.

[Grimly]

The tiniest amount is just enough to do the job.
It gets a bad name because of bad application and over-use.
Not its fault it's been used by many idiots with no clue.

[ddaniels]

Agreed. I cut the smallest hole possible in the applicator to allow it to squeeze through. You still get some that squishes out though when tightening down the screws.

[1_v8_merc]

Geez, I think half my bike is held together with RTV, and that was like 7 years ago. I was in a hurry at the time and needed it for transportation, so I patched up oil leaks, made gaskets, patched fuel leaks. It never ever leaked, so I never bothered replacing the gaskets, lol.