V-STAR Crankcase Problem

 

I recently discovered that my V-STAR 650 Classic is leaking oil. It is a
very minute leak, about a half dollar accumulation under the crankcase over
a 48 hour period.



I took the bike into my local Yamaha shop and the service manager diagnosed
the problem to be on the left side of the crankcase.



Let me elaborate:



Within the crankcase is the oil filter mount which is fastened by a number
of bolts. One of the bolts runs from the oil filter cover all the way
through to the engine block. This is where the problem comes in.



Apparently, because the threading within the crankcase that takes the bolt
is made of aluminum, it is easily stripped by overtightening this bolt when
servicing the bike. What has happened is that the thread has stripped and as
a result, the said bolt does not have a tight seal so the o-ring isn't
sealed perfectly so it seeps oil.



The mechanic said that he had seen this before on older V-Stars and he felt
it was a design flaw because it was very easy, in his opinion, for the mere
mortal weekend mechanic to over-tighten this bolt, thus stripping the
thread.



The mechanic, who hasn't given me any reason to not trust his ability or
judgment basically said that there are two choices:



  1.. Rebuild the crankcase ($3000+ parts and labor) or
  2.. 2. Re-fit the stripped thread with a dowel-like fastener that seals
the stripped thread and provides a new thread hole in the center of the
dowel to match the bolt. What this accomplishes is a primitive seal on the
stripped thread while providing a new thread to match the bolt. About $100,
worth a try, right?.


He did warn that he noticed a small hairline crack around the old thread
hole, but felt confident that for $100 it would make sense to try it and see
what happens.



Well, if you've gotten this far, then you can imagine where this is going
next.



As fate would have it, the crack is significant enough to prevent a tight
seal between the cover, o-ring and crankcase and I am still leaking oil,
however so slightly.



So, we are back to option 1. Rebuild the crankcase.



So I find myself in quite a dilemma. I paid $3700 for this bike 3 months
ago. To put another $3K into it doesn't make much sense.



My mechanic feels that the leak is purely cosmetic and that the bike is
mechanically sound. Unfortunately, even a little bit of oil blows all over
the lower crankcase cover which looks like crap.



So I am torn between fixing it, or selling it (with full disclosure of
course).



Is anyone else familiar with this problem?



Any other options for professionally fixing this?






--
Rick G. Garibay
MCP

 



helicoils. one will cost less than 2 bucks and you can do it
yourself. they've been around since the 30's. honda drains
used to be notorious for that. it is an effective fix.
but 100 bucks for one is a RIP OFF!

 

Rick G. Garibay wrote:

J-B Weld the hairline crack. Used it on a cracked case 6 years ago. No
leaks or weeps.

 

wrote:


or even have it spot welded for cheap. have to drain the oil
and protect the rest, but a good welder won't need much
space. then use a helicoil for the threads......cheap,
effective and you won't see a thing.