bentwheel
Serious Thumper 2005 No Login
   
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Ride free, citizen
Posts: 658
Sarnia, Ontario, Canada
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During the winter I performed routine maintenance on my Savage, in fact I posted with pics on my progress and findings a couple of months ago. Black Betty is 19 years old now and had developed several small oil leaks that were bad enough to send an oil mist to the complete left side of the bike. Most of it complements of the drive belt. There was obvious evidence of leakage from the pulley seal. I suspected the oil seals and gaskets were original so I replaced them all. Starting from the top down I changed out the starter motor seal: drive pulley/countershaft seal, RTV silicone to the rubber plug at the generator harness, shift lever seal, shift cover gasket, and left primary cover gasket. There, all conceivable points of oil leaks were halted with new parts. I kept off the pulley cover so I could better monitor the area for the unthinkable. After 500 kms of riding all the changed parts are oil tight and there is absolutely no oil dripping from any of them. But wait, whats this, a rather large drop of oil is clinging to the lowest area of concern. The black harness that contains the yellow generator wires that runs in the the boss on the engine case then bends back up towards the battery box is leaking oil. Let me repeat that. The electrical wireing harness is leaking oil. No it's not oil from outside the harness ( at the rubber plug) leaking down the harness to form a drop. Remember, I said ALL exterior leaks were sealed. A close inspection of the harness reveals a crack in the material at the crease and oil can be squeezed out from INSIDE the harness. I have to assume oil is entering the harness from inside the generator primary cover. It looks like the rubber sealing plug has fatigued, so I will have to seal the wires from the generator harness on the inside as well. Hold on, I have just had a thought. The harness enters the cover above the oil line so it is pressurized, splashed oil that got into the harness. I highly suspect I had excessive crankcase pressure from using a too high oil level (purposely done for long trips with a leaky engine and thereby exacerbating oil leakage from marginal seals/gaskets). Now that I'm using a reccommended oil level with less crankcase pressure I am going to keep an eye on that harness and see if the oil stops entering the harness. You know, I have seen smoke come from an electrical harness and now I've seen oil.
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