stator casing leak help!!!!

[biggeeman]

Need help with my 03 zx6r this fault been going on for a while now I am 2minutes away from taking a sledge hammer to this bike.

To cut a long story short I have a oil leak at my stator casing between that and the engine itself myself and a garage have tryed all sorts, 3 stator casings rebuilt all the threads with timeserts to ensure a good nip up, fancy gasket sealants which dry like rubber still leaking but only if you ride hard oil will be found on the very bottom underside of the casing. The garage I give it to put on a dyno to test it after they do work to it they then give me it back saying thats it sorted I go blast in it and I have oil all over ma boot lol its really annoying .If you ride the bike under 10 grand there will no oil start giving it some, bang everywhere park it up overnight no drips nothing In my opinion it is as if when I ride hard its as if the stator casing is slightly parting ( opening ) away from the engine possible?? Or there is a warp in the block. The leak is definetly between the stator casing and block there is no cracks on the engine or the casing for that matter.

Question is can I apply jb weld or something like that, between the casing and engine to form like an outside gasket type thing to stop this oil leak.

Any help would be appreciated.
____________________
lol your funny

[Vincent]

Could be the engine casing has become porous, there shouldn't be much pressure behind there so I can't see that the oil is being forced through between the two casings. Maybe you could coat the inside of the case with something that won't let the oil through. Not sure what though.
____________________
Space Is Deep

[biggeeman]

[Vincent]

[Ariel Badger]

Sounds like porosity in the casting, not common in die-casting but it can happen, Very common in sand casting.

You need to clean it with petrol and use dye penetrative spray on the casting and look for symptoms of any flaws.
____________________
Bikers make great organ donors, get 115 on your licence today.

[Vincent]

Do a bit of research for Loctite Resinol, I can't remember if it's oil resistant or not.
____________________
Space Is Deep

[biggeeman]

Cool cheers for ideas guys I can try upload pictures tommorow of what is going on if its dry I can take the bike a quick blast then upload photos of where I have oil leaking that maybe make this a bit easier.

There is definitely nothing obvious on the inside of the engine and casing for that matter. Proper nightmare lol
____________________
lol your funny

[moonzoomer]

Buy a secondhand casing, anything else is hardly worth the hassle . Last thing you want is contaminated oil especially in a Kwak with their white white metal bonding system for their big ends, an air bubble is enough to scrap them as standard.

[stinkwheel]

Make a gasket from a cornflakes packet?

I've never had one leak so if it's a leak round the actuaql join, that ought to do it. Marginally thicker than standard gasket paper and a waxed finish make it the ideal gasket material.

Cleaning and degreasing the underside of the bike then applying some talcum or cement dust should allow you to localise exactly where the leak is coming from.

It can be a mistake to assume that because an oil drip is in a certain place, that's where the leak is. I remember a mate of mine had a moto guzzi which, in total defiance of all logic, appeared to be leaking oil from its back left indicator. Turns out it was actually coming from the rocker cover gasket but there was no obvious oil on this.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Vincent]

Look out - I used a cornflake packet gasket on my CB750 to get me out of a jam years ago and the end of the crank welded itself onto the inside of the cover I've used them elsewhere without problems mind.
____________________
Space Is Deep

[stinkwheel]

[Vincent]

[biggeeman]

Right guys the latest,

Put some concrete dust around casing what an idea by the way, that has allowed me to come up with this conclusion.

I have no silicone/gum whatever its called for about an inch at the crank halves I am 99.9% sure this is where the leak is. I have put a metal epoxy on the outside of it going another blast tonight hope it holds wish me luck dont want to take that stator casing back off.see picture for what I mean
[img][/img]
____________________
lol your funny

[biggeeman]

Job done thanks guys for the advice if you can see the picture that is what has solved the problem it was the crank case halves all along.
____________________
lol your funny