Motorcycle Repair: Leaking Clutch Cover, 2001 suzuki sv650s, yamabond

Question
I own a 2001 Suzuki SV650S.  A while back, I noticed a small amount of engine oil leaking out of the bottom of the clutch cover on the right side of the bike.  I ordered a new O-ring and after replacing the O-ring, the leak continued. It is actually leaking more than it did before!  I am running 5w-40 synthetic oil instead of 10w-40 synthetic.  Do you think the oil is too thin?  Could the O-ring be faulty or the cover is warped?  Should I use RTV sealant or get a bigger O-ring?  I would appreciate your advise.
Thank You,
Justin Tibbetts (E-Mail: [email protected])

Answer
Hi Justin,

Q:  "...Do you think the oil is too thin?"

A:  No. The oil is fine.


Q:  "...Could the O-ring be faulty or the cover is warped?

A:  Yes, it's possible that the new o'ring is defective or was damaged or pinched upon installation. Yes, it's possible that the cover is defective.


Q:  "...Should I use RTV sealant or get a bigger O-ring?

A:   No. Do not use RTV on your motorcycle. Use one of the following: Suzuki Bond, Yamabond, or Honda Bond.

If a factory o'ring for that application was installed, you're done. Do not try installing a bigger o'ring. Instead, find the source of the leak and repair accordingly.

For difficult to find leaks, I use Dr. Scholl's Foot Powder Spray. The powder sprays on pure white. Oil seeping through turns the powder brown. Clean-up is easy. You may find a less expensive product to use. Dr. Scholl's costs about $9 per can.

Basically, you'll have to verify the source of the leak is actually the o'ring seal. It may be from another source.

Respectfully,
Mark Shively