Oil leak/slave cylinder

Buckwhylin · 10-15-2010, 07:46 PM

Wondering if someone could help me out,there is a small amount of oil/hydraulic fluid coming from around the slave cylinder region on my motorbike, clutch is working fine ,do I need a new gasket or does the o ring need replacing

bajadog · 10-16-2010, 03:06 PM

Sure,

What year model ?

Buckwhylin · 10-16-2010, 09:37 PM

Quote:

Originally Posted by bajadog

Sure,

What year model ?

It's a sx 2005 model

bajadog · 10-17-2010, 10:39 AM

Quote:

Originally Posted by Buckwhylin

Wondering if someone could help me out,there is a small amount of oil/hydraulic fluid coming from around the slave cylinder region on my motorbike, clutch is working fine ,do I need a new gasket or does the o ring need replacing

Okay Buck,

There is an o-ring for the slave cylinder piston:

SKU: 0770300015
O-RING 30,00X1,50 NBR 70

and a gasket for the slave cylinder cover:

SKU: 59032065000
GASKET FOR SLAVE CYLINDER.

They run $1 each. If you are going to go through the hassle
of taking the slave cylinder off, you might as well change
the o-ring too. I'd guess the gasket is your culprit though.

Good luck.

Buckwhylin · 10-17-2010, 08:13 PM

Thanks baja.

Quote:

Originally Posted by bajadog

Okay Buck,

There is an o-ring for the slave cylinder piston:

SKU: 0770300015
O-RING 30,00X1,50 NBR 70

and a gasket for the slave cylinder cover:

SKU: 59032065000
GASKET FOR SLAVE CYLINDER.

They run $1 each. If you are going to go through the hassle
of taking the slave cylinder off, you might as well change
the o-ring too. I'd guess the gasket is your culprit though.

Good luck.

dj77kit · 11-04-2010, 09:38 PM

I have the same problem with my 2002 EXC 520. I have not taken it apart yet but per what I have read that the slave cylinder gasket was not added until 2003. Is this true? It seems odd to think that the cylinder would sit metal on metal. I assume that the gasket for the piston is the same. Do you think there would be any harm in adding the gasket?

Thanks in advance.

bajadog · 11-05-2010, 07:15 AM

Quote:

Originally Posted by dj77kit

I have the same problem with my 2002 EXC 520. I have not taken it apart yet but per what I have read that the slave cylinder gasket was not added until 2003. Is this true? It seems odd to think that the cylinder would sit metal on metal. I assume that the gasket for the piston is the same. Do you think there would be any harm in adding the gasket?
Thanks in advance.

You are right. The 2002 model has no gasket between the slave cylinder
and the case. That is really strange metal to metal, unless they used
a Permatex type sealant.

The 2002 slave cylinder is PN 54732061044, the 2003 is PN 59032061044.
For a $1, I would try it, just be careful and tighten the cover down in
a cross pattern.

Buckwhylin · 11-08-2010, 04:44 AM

Ok thought I would post on how I'm going with my oil leak.I ended up getting a new gasket and o ring for the slave cylinder that had a leak.
Well as it turned out I found the cause of this leak.I removed the slave cylinder and to my disgust the last owner of my bike has stripped the thread and inserted a m6 helicoil.I didn't think that this was so bad anyway I put the new gasket and o ring on and put the slave cylinder back on bled the clutch on torques the bolts to 10nm.I started the bike and guess what it's leaking worse than before

I'm a shattered man now because the helicoil doesn't seem to be holding the bolt and I can't go any bigger with another helicoil!
It looks like I will have to buy a left side engine case to fix a problem which I thought was only going to take a o ring and a gasket. Has anybody got any ideas or a train of thought on how I might be able to fix this problem without splitting the cases?

bajadog · 11-08-2010, 07:23 AM

Buck,

Can you use a threaded insert?

On my XR600, I stripped out a case screw towards the bottom
of the case. No matter what I did it would weep oil.
I drained the oil, and using a long drill bit (blind hole) I drill
the stripped threads out, then tapped to use these inserts.

If you go to this web site, then to the center image (thread locking),
the right image on the next page are the liquid/gas tight inserts.

Have a look.

http://www.mcmaster.com/#thread-repair-kits/=9mn2m0

Buckwhylin · 11-09-2010, 02:30 AM

Baja thanks for the tip, today i ended up taking the slave cylinder off again,and ive put some loctite 515 around the oring and both sides of the gasket, gonna give it 24 hours to cure then bleed the clutch and see if there are any leaks!if this doesnt work i will try to remove the helicoil and replace it with a press in threaded insert!!!Ive got a question for you that you might be able to help me with.If all else fails and I have to replace the left side engine case,will a 2004 sx 450 case, fit the right side 2005 sx 450 case.
Any input would be great

Thanks again buddy

Quote:

Originally Posted by bajadog

Buck,

Can you use a threaded insert?

On my XR600, I stripped out a case screw towards the bottom
of the case. No matter what I did it would weep oil.
I drained the oil, and using a long drill bit (blind hole) I drill
the stripped threads out, then tapped to use these inserts.

If you go to this web site, then to the center image (thread locking),
the right image on the next page are the liquid/gas tight inserts.

Have a look.

http://www.mcmaster.com/#thread-repair-kits/=9mn2m0