New motor in, Couple problems... Help!

[Scrapyard]

Well, I finaly found a new lump for my bike but it didn't come without its own set of quirks. After about 12 hours of musceling the thing in, one broke motor mount bolt, hooking it all up, missing a hiden crank triger conection and a dead battery I finaly got it in and running. It was pretty funny though. My skiny ass lifting up the whole bike and droping it over the motor. Wish I had a pic of it. Anyway, down to the point. It runs good but it leaks coolant and oil. The oil is coming from the clutch cover. The motor looks to have taken a low side at one point and cracked a bolt hole. Also there is a crack around the oil fill hole. I'm gona swap the cover from my old motor on and see what happens. Coolant is coming from what looks to be a weep hole facing twards the front. It's on the side of the adapter plate that bolts to the right side of the block. The plate goes around the clutch and houses the water pump. I'll attach some pics so you can see what I'm talking about. My question is, is water suposed to come fromt that weep hole? There's what looks to be a water channel that runs from the outside of the block to the bearing for the water pump impeler. I shined a flash light in there and can see the outer edge of the bearing. Also the end of the hole looks to be threaded. But neither motor had a bolt in there . Any light you can shine on this matter is greatly appreciated.

Back of plate:

[Scrapyard]

Weep hole in side of plate.

[Scrapyard]

Side of motor

[TLSBill]

Clean down the metal on the engine side of the clutch cover good and smooth, no leftover crap and you'll be better off. Better off using an aluminum cover that won't flex too becuase I'm not sure how well the plastic one'll hold with a missing bolt.

Can't help on the weep hole other than to say get all new seals.

[Scrapyard]

Cacked ass side cover. Right befor I pulled it off I cranked up the bike. When I reved the motor the cover would shift slightly and a couple drops of oil would come out. If you look around the oil fill hole you can see 2 hir line cracks that go to the mounting edge. Wierd part is it leaks at the bottom of the the cover

[SDTLR]

Those crappy stock cover all leak after a couple years. especially if he put it down (which it seems since one of the bolts is cracked.

Get a billet one, or clean the hell outta it, and replace the gasket.

:dunno about the other leak

[Seca]

Thats not a water pump bearing its a seal. Oil is getting past that and running out the weap hole. Replace the oil seal and it will stop. While you are at it just go ahead and replace all the seals for the water pump.

[Scrapyard]

Cool, thanks ya'll. I pulled the parts that are screwy from the other motor. I'm gona go swap them now and throw down some RTV and see if that stops it. I'll let you know. TO THE BAT CAVE!

[Steve TLS]

The water pump has 2 seals, an oil seal and a water seal, and they're seperated by an airgap, and the airgap is vented to the hole in the engine case cover. So if one fails it stops then from being able to mix, i.e. water in your oil or oil in your water.

Nothing should come out of that hole. and it shouldn't be blocked up.

[Scrapyard]

I just pulled that seal apart. I see what you're talking about. I swaped the whole deal from my old motor over. and water is still runnung out. The screw that holds the impeller onto the shaft was very loose on the new motor. It seems the seal is held tight by the impeler pushing against it. Do you think that bolt needs to be tourqued down a lot for it to seal properly? Cause it's still spilling coolant with the other parts on.

[univip3r]

if you are unable to identify exactly where the leak is coming from let me know. I do non-destructive testing (ie, i find cracks where the eye cant see) in addition to my regular stint as a network dude. For steel I can do magnetic particle, for aluminum and plastic i can do dye penetrant testing...let me know via PM.

-u

ps. this goes for anyones project. I am about to start doing ultrasonic testing so consider me a resource if needed.

[Scrapyard]

Well, I think I fixed it. It's not leaking anymore at least. After pulling the water pump apart again, I retorqued the impeller to factory spec. Still leaked. Then after stareing at it for about an hour :dunno I got an idea . Let's stick something in there, wiggel it around and see what happens . Some how, it worked . I'm still a bit paranoid but If it holds together for at least a week I'll count my blessings and move on. Thanks for the help guys. I appreciate it.

[Steve TLS]

One other thing I've heard of is the shaft sometimes needs a real good clean up to stop the leak / seal failing again.

Give it a light going over with fine sand paper if you have to pull it apart again.

Hope it holds together.

Originally posted by univip3r
if you are unable to identify exactly where the leak is coming from let me know. I do non-destructive testing (ie, i find cracks where the eye cant see) in addition to my regular stint as a network dude. For steel I can do magnetic particle, for aluminum and plastic i can do dye penetrant testing...let me know via PM.

-u

ps. this goes for anyones project. I am about to start doing ultrasonic testing so consider me a resource if needed.

Generous offer Non destructive testing ? Where's the fun in that