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[Twolanerider]

OK Don a little trick we used to do with race motors before most people even heard of coatings....it has been around for a long time....the same coating that is put on piston skirts, valve stems, intake runners, connecting rods, gears..etc....can be sprayed in the case and it will seal any and all voids that can and will cause leaks. We used to get engines where the blocks were too porus and we would have them treated and the oil seepage would stop.
HPC  SO2

That's one I've used before Brian.  When I still played circle track and built my motors used it.  They're a Kiwi company if I remember right.

The SO2 I remembered as being a product to cause a surface to shed oil.  Like you'd want on a windage tray or inside of a pan or rocker housing.  Could see how they might help with a porousity problem too but less comfortable with what is probably a crack.  It's been awhile but thought I also remembered the product not having a long term life cycle.  Would hate to have re-fix this every year.  Taking the pan off has already gotten old.

Will do more homework and see what the company has to say.  Saddlebags are back on it and all the tools are put away now though.  It needs a break from me before we decide what will happen to it next.

[hogasm]

I told a buddy about the coatings and he took his Hyabusa trany and did the inside of the case and the gears. He also put ceramic coated bearings in the trany. His 1/4 mile times went down .6 seconds. Blew us away with the increase in speed that did.
No motor work changes only the trany

[Twolanerider]

I told a buddy about the coatings and he took his Hyabusa trany and did the inside of the case and the gears. He also put ceramic coated bearings in the trany. His 1/4 mile times went down .6 seconds. Blew us away with the increase in speed that did.
No motor work changes only the trany

That's amazing.  Hells bells, if I did that with the red bike when its tranny eventually gets fixed the thing will be able to achieve vertical climb!

[Twolanerider]

Was asked in a PM how this leak problem had eventually sorted out.  That reminded the story never got finished.

Leak was through the tranny case.  Even though anything else was eliminated (multiple times!) so that had to be it I'm still not sure I believed it until I saw it.

First off the oil cavity does go up quite a bit higher than the exterior line we see separating the tranny case and oil pan.

[Twolanerider]

This image is looking at it from the outside of the case and below the tranny side cover.  Where the screw driver is pointing is where the oil was coming through the case.

[Twolanerider]

This is looking "up" at the bottom or inside of the tranny case.  The "ceiling" of the oil pan so to speak.  Can't see it well (or at all) on the low res pics here but where the screw driver is pointing is where a hair line crack is in the case.

[Twolanerider]

Of course to fix it chit has to be torn all apart.  Oh well, it's fixed and has been for awhile now.  Very glad the old girl is running well and reliably again.

While apart it got a new 45 amp rotor inside the primary and lots of general looking over.  Also got winterized during reassembly (i.e., the heated black seat went on in place of the summer tan saddle).

[Twolanerider]

Still don't know nor ever will know why the leak started in the place it did only after the pan was pulled to replace the gasket for a leak in an entirely different area.  Hairline crack that needed the stress of a bolt going out and back right next to it makes the most sense.  But it's an odd one no matter what.

After this problem presented also don't know whether it only leaked after being run for awhile was a result of some thermal expansion, the buildup of crank case pressure or a combination of the two.  Probably the latter. 

It is fixed though.  It also ended up with the red oil pan back underneath it as it should have.  So the red bikes runs well, doesn't leak, charges better and looks better.  I can live with that.

[porthole]

Of course to fix it chit has to be torn all apart.  Oh well, it's fixed and has been for awhile now.  Very glad the old girl is running well and reliably again.

While apart it got a new 45 amp rotor inside the primary and lots of general looking over.  Also got winterized during reassembly (i.e., the heated black seat went on in place of the summer tan saddle).

I seem to recall another red bike looking like that some time ago 

[Boatman]

How would you like to be a tech at a dealer figuring this out (multiple times) or the poor customer?

Know it was a PIA but knew you would figure it out.  It was in a spot where the most logical explanations would be the side cover gasket or pan gasket (even though oil doesn't run up hill).   You didn't need this much experience.  Another job under the "school of hard knocks"..   No book or tech school would teach you this.  Good job!

[porthole]

So did you get a new trans case? When I looked at ordering mine I was told 2-5 weeks for a delivery.

[Boatman]

I seem to recall another red bike looking like that some time ago  

You red bike guys are some sick sumbitches.    

[Twolanerider]

So did you get a new trans case? When I looked at ordering mine I was told 2-5 weeks for a delivery.

Jenni said to expect "a week or so" for a case.  Also was surprised to learn from her that a replacement tranny case came in bare without a VIN derivative.  So ordered a case and bearings and the other bits that would need that weren't already here.

Then literally 12 hours after ordering the new case a good case showed on eBay for $95 buy it now including freight.  The SERK project unexpectedly got a new tranny case to replace the busted one.  No need to worry if the TIG repaired case would ever be a problem

[Twolanerider]

How would you like to be a tech at a dealer figuring this out (multiple times) or the poor customer?

Know it was a PIA but knew you would figure it out.  It was in a spot where the most logical explanations would be the side cover gasket or pan gasket (even though oil doesn't run up hill).   You didn't need this much experience.  Another job under the "school of hard knocks"..   No book or tech school would teach you this.  Good job!

Amen to that Brother Bob.  Pulling the pan off the second (or third or whatevers) time did test my patience though.  New parts are a cure for many evils though....

[Twolanerider]

You red bike guys are some sick sumbitches.    

Busted cases, cracked cases; at least they didn't get burned down !