Bit off more than I can chew?

[TLSean]

I wish I had a digital camera so I could explain this more easily, but here goes. I recently noticed that I was leaking coolant from the small hole that is to the front of the clutch cover. I was told that this is a common problem and that there is a $4.00 seal that can be easily replaced. No problem I thought. I ordered the seal and began disassembling the cover for the clutch and the water pump seal area. I drained the oil and the coolant and took the screws all out, hopefully in an order that I will be able to easily install them again according to length. Once I got the cover off, I found that I was actually not leaking from the $4.00 seal area, but the gasket that surrounds the entire cover had cracked. I am kind of bummed now because I have my bike completely apart in my garage and I need to order this other part (which I have to find the part number for). Has anyone else done any work on this area? I am getting nervous about putting the whole thing back together and having it run correctly. Any advice or words of encouragement would be appreciated. I think I am an average to slightly above average mechanic and I was told this was a fairly easy change. Now seeing all the gaskets I have moved around...well, hopefully it won't be an issue. Thanks for listening.

[jupiter33458]

The Factory SUZUKI Service Manual is the best thing to have laying around.
Don't fear working on your bike... belive me.
I spent $$$ going to a A.M.I. in Daytona to "learn" about bikes. What I came to understand is that even people with minimal skills CAN work on there bike IF they can overcome there fear.

No worries. Get her done.

[SDTLR]

You need a clutch cover gasket?


No worries bro, easy enough someone will have the part #


But

how about buying a couple raffle tickets for a camera? problem solved.

[dragonbro]

if it was comming from the weep hole then the leak was from the water pump shaft seal. you will also need the gaskets for everything else you took off to get to the waterpump seal. not a big deal........you can do it. just take your time and post some pics if you get lost.

[bikeman]

to have faith in yourself

to have faith in yourself is to achieve anything. get all the facts, look at the manual, ask question , and proceed slowy,and i bet you will get it. Good luck!!

[TLSBill]

Get youreself a manual (we have PDF's areound here..) and check Ron Ayers web site for your parts diagram forthe part #.. Good luck!

[Steve TLS]

www.jiffypark.com

[z0s0]

whered jiffypark come from?? thats an awesome collection of all the resources from everywhere, i hope it builds
how bout hosting the sticker files??

[TLRguy]

I just finished this arduous process a month ago. I was a bit nervous at first, but I consider myself to be an above average mechanic so I tackled it.

You have a mechanical seal and an oil seal in there. Look at the weep hole and decide whether or not it is oil or coolant coming out. I would replace both anyway, but its good to know. Ensure when you have it all apart that you sand down the water pump shaft with a fine grit sandpaper and put a large amount of grease back on the shaft.

Take the seals out carefully and ensure that you don't dig a groove into the cover. There is a metal piece between the two seals that you must not break when using a socket. (trust me, I did it and had to buy a whole new cover) Use caution when putting the cover back on and go very slow. All of the bolts are self explainable so don't worry.

Just PM me if you need more guidance.

[Steve TLS]

Originally posted by z0s0
whered jiffypark come from?? thats an awesome collection of all the resources from everywhere, i hope it builds
how bout hosting the sticker files??

Jiffypark is a member here who has hosted the info for us to snaffle

[TLSean]

got pics

Here is the problem area. I have ordered a new seal and it should be in Wednesday. This blows. Not only is my bike in pieces in my garage, I need to keep my truck parked outside during this time.

[TLRguy]

That's an easy fix my friend. Place some grease on both sides of the new gasket and on the shaft. BE SURE TO PRESS THE CLUTCH COVER ON SLOWLY!!! Do not push it or you will rip the oil seal! Then you will have a real pain in the ass to fix, and you'll be really

[Slapper]

I wish I had seen this thread sooner.

I have that gasket sitting in my basement -- brand new, in its plastic.

And since I don't have a TL-R anymore, well...

[TusherTLR]

yo TLSean...update? Hope you are still plugging away. Remember to label everything! If you are not sure where things go...either take pictures (that way you can share them with us) or label things to make it easier on yourself later.

[TLSean]

I have that gasket sitting in my basement -- brand new, in its plastic.

DOH!!

No progress to report yet. The gasket is supposed to come in tomorrow. I will know more then. Any specific grease I need to use?