External air leaks found

[JZ05220r]

I decided to look a bit harder for leaks during a leakdown test today. I found a total of 4 different leaks. The first leak I found was around the kips inspection cap, the second was the bolt with the two copper washers that sits below the inspection cap. The third leak is around the top right reed cage bolt. The fourth and most disappointing was along the front crank case seam under the cylinder. I’m 100 percent positive these are all air leaks. Is this really typical for an engine fully rebuilt with 12 hours on it? I can imagine that the crank seals leak. I may pull the flywheel and stator to check the left side crank seal but their is no oil under the stator cover. Ignore the coolant, it dripped when I removed the cap and migrated. Thanks

[SS109]

If the case is leaking that is a big one. It could explain the poor running, oil consumption, and the impossible to get it jetted correctly issues. No, at 12 hours you shouldn't be seeing anything like this.

[JZ05220r]

If the case is leaking that is a big one. It could explain the poor running, oil consumption, and the impossible to get it jetted correctly issues. No, at 12 hours you shouldn't be seeing anything like this.

Thanks man. Sent Jeff an email of the picture maybe he can make this right. If he doesn’t respond I’m just going to move on. I’m relieved to have found this finally but, I’m exhausted of all the testing and everything I have done to try to get the bike enjoyable to ride since June.

[Tyl3r]

I think you should split those cases, fix the leaks, reseal, and put it back together. Its really not that bad, I followed this thread when I did it and I didn't have any troubles viewtopic.php?f=77&t=12241&hilit=splitting+cases

[JZ05220r]

I think you should split those cases, fix the leaks, reseal, and put it back together. Its really not that bad, I followed this thread when I did it and I didn't have any troubles viewtopic.php?f=77&t=12241&hilit=splitting+cases

Thanks for that link I have thought about it but the thing is
I spent 1500-1600 dollars having it professionally rebuilt.

[Slick_Nick]

I think you should split those cases, fix the leaks, reseal, and put it back together. Its really not that bad, I followed this thread when I did it and I didn't have any troubles viewtopic.php?f=77&t=12241&hilit=splitting+cases

Thanks for that link I have thought about it but the thing is
I spent 1500-1600 dollars having it professionally rebuilt.

It's hard to get anyone to guarantee their work anymore. This is why I always do everything myself, so I know it's been done right. Pull the engine, see if the shop will rebuild it for you under warranty, but if not, at least when you do it yourself, you'll have assurance that it's been done properly.

[bufftester]

+1 what Nick said...do it yourself, have the peace of mind it's done right, and own the mistakes if not (and of course learn from them).
Hopefully the shop stands behind their work, though that is becoming increasingly rare these days.

[Tyl3r]

Ouch, that is a lot of money for it to still not be right. That is also why I try to do absolutely everything I can on my own. Very sorry to hear about your luck!

[Molly's 70]

If you have to rebuild it yourself, you have a lot of support here. Post pictures & ask questions. I am here everyday.

[JZ05220r]

If you have to rebuild it yourself, you have a lot of support here. Post pictures & ask questions. I am here everyday.

I appreciate it. I’ll see what they say. Thank you

[JZ05220r]

Ouch, that is a lot of money for it to still not be right. That is also why I try to do absolutely everything I can on my own. Very sorry to hear about your luck!

Thanks man and yea I know. The time I have put into it trying to get it right is what really gets me. Must be well over 24 hours of my time.

[JZ05220r]

+1 what Nick said...do it yourself, have the peace of mind it's done right, and own the mistakes if not (and of course learn from them).
Hopefully the shop stands behind their work, though that is becoming increasingly rare these days.

The shop is very well known. You can see it in my signature.

[JZ05220r]

I think you should split those cases, fix the leaks, reseal, and put it back together. Its really not that bad, I followed this thread when I did it and I didn't have any troubles viewtopic.php?f=77&t=12241&hilit=splitting+cases

Thanks for that link I have thought about it but the thing is
I spent 1500-1600 dollars having it professionally rebuilt.

It's hard to get anyone to guarantee their work anymore. This is why I always do everything myself, so I know it's been done right. Pull the engine, see if the shop will rebuild it for you under warranty, but if not, at least when you do it yourself, you'll have assurance that it's been done properly.

Im hoping they’ll help me make things right. I called them twice a month ago and left my name and number through voicemail, never got a call back. My emails were ignored until today when I sent them the pictures of what’s going on. They acknowledged the leak and asked me if I took the top end apart which I didn’t. Thanks

[JZ05220r]

I’m sending the engine back and it will be moved to the front of the line. I asked them to replace the crank seals again as I was still losing trans fluid. I’m also going to have them inspect some wierd cylinder markings. They look like they were caused by overheating.

[John_S]

I’m glad to hear it’s going to get fixed up. Jetting it next time should be straight forward with expected results to changes made.

[JZ05220r]

I’m glad to hear it’s going to get fixed up. Jetting it next time should be straight forward with expected results to changes made.

I’m excited to give it another shot. I also have a 1991 Kdx I am in the process of restoring. I’ll have it done sometime this winter and post some pics on how that comes out. I already have all the parts, just waiting on a few things.