Leaking stator cover issue

[Cupcrusader]

Hey all, it’s probably been about 10+ years since I’ve been on the forum, so it’s good to be back! I totally forgot my username and email I used, so it’s back to square one.

my current issue: The hawk I recently picked up had a leaky alternator cover (leak was coming from the bottom bolt in the 5 or 6ish o clock position) so I decided to order a new gasket from hord and change the oil. After all was said and done, it was still leaking after warming it back up. On top of that, I overtorqued that same bolt and snapped the head…I know…..After I extract said broken bolt, I guess my questions are:

1) Had anyone else had this issue? Specifically a leak from the bolt that also holds that small bracket for some wire (it lays in between the cover and block)

2) is it possible to use some sort of liquid gasket?

3) is a new cometic gasket change needed after this mishap?

Any input would be much appreciated. Thank you wise ones!

[DrPMC]

That sounds like something is broken or damaged. That joint would normally be oil tight with just the gasket and a smear of sealant (I don't use sealant but grease both sides of the gasket, so I can use it again).

Breaking a 6mm bolt sounds like far too much torque. I have replaced all my cover screws with stainless socket screws and would just tighten them evenly with a t handle driver. There isn't much pressure inside a NT650 engine - as long as everything is clean, undamaged and properly assembled it won't leak.

[6]

Are you 100% sure you have the correct length bolt on there?


And couldn't possibly be coming from higher up and just dripping from there?

Also, have had case covers that have been damaged, welded back, repaired, smoothed, and they still leak like crazy. Cover may be an issue.

[Cupcrusader]

Definitely agree that it was too much torque. I guess my thought was if I tightened it just a tad bit more I could get the oil to stop dripping. Huge mistake

I remember there wasn’t any cracks on either side of the case or cover so I really don’t know what it could be.

what type of sealant would one typically use?

[Cupcrusader]

Are you 100% sure you have the correct length bolt on there?


And couldn't possibly be coming from higher up and just dripping from there?

Also, have had case covers that have been damaged, welded back, repaired, smoothed, and they still leak like crazy. Cover may be an issue.

@6 that’s actually a good point with the correct bolt size.. when I originally pulled the bolts off I stuck them in some styrofoam foam to copy the original orientation of how they were. However, the bike has 90k miles on it so I don’t know how many times that thing has been changed/ removed.

Out of curiosity, how many different bolt sizes go into that cover? I think I noticed two..

I know this bike has a lot on the clock, but it was $800 for a cherry looking bike WITH ORIGINAL REAR FAIRING TABS UNBROKEN?!? lol

[Ziggy]

Make sure the rubber collar on the stator wire is sealing. Collar is between the crankcase and stator cover.
There are 2 different length bolts used to attach the stator cover to the crankcase.
See below link for info.

Honda Motorcycle 1988 OEM Parts Diagram for Left Crankcase Cover | Partzilla.com

[6]

Make sure the rubber collar on the stator wire is sealing. Collar is between the crankcase and stator cover.
There are 2 different length bolts used to attach the stator cover to the crankcase.
See below link for info.

Honda Motorcycle 1988 OEM Parts Diagram for Left Crankcase Cover | Partzilla.com

I usually put a bit of rtv on that rubber boot.

[6]

@6 that’s actually a good point with the correct bolt size.. when I originally pulled the bolts off I stuck them in some styrofoam foam to copy the original orientation of how they were. However, the bike has 90k miles on it so I don’t know how many times that thing has been changed/ removed.

Out of curiosity, how many different bolt sizes go into that cover? I think I noticed two..

I know this bike has a lot on the clock, but it was $800 for a cherry looking bike WITH ORIGINAL REAR FAIRING TABS UNBROKEN?!? lol

Sounds like you paid for the bodywork and got the bike for free. Not bad.

[Cupcrusader]

Yeah, I was able to get it started with a good smooth idle. Other than that dumb leak, she’s good to go. At the very least, I came into this with the expectation of having a clean stock bike with good spare parts to rebuild my old hawk, I started to build in high school.

thank you all for the insights! I’ll take a look at the bike to see if the leak is actually coming from that grommet somehow. I’ll update you all soon.