CBR600F ? Oil in coolant

[Serendipity]

Story so far –

* Coolant expansion tank overflows with oil/water mix porridge. (Almost a year ago)
* No contamination in oil, just oil getting into water.
* Suspect head gasket or oil pump failure.
* Paddy Blake from BCF suggests o-ring failure in oil cooler.
* Bike goes into storage for a year until this month when I finally start working on a fix.
* Bike starts on second push of button after standing for a year.
* Drain oil – all clear, no contamination.
* Drain coolant – all clear until the last bit – oil floats I guess – then a bit of porridge.
* Remove radiator and exhaust system and take off the oil cooler.

So here we have more porridge. This stuff came from the coolant hose to the bottom right of the picture.
https://i221.photobucket.com/albums/dd227/serendipity_uk/CBR600FR/IMGP4118a.jpg

The cooler dismantled: Oil passes through the radiator thing while the coolant flows around it inside the cooler housing. More porridge inside the cooler.
https://i221.photobucket.com/albums/dd227/serendipity_uk/CBR600FR/IMGP4121a.jpg

The o-rings where the radiator fits into the cooler body were indeed totally knackered. Both were hardened and misshapen. Slightly more concerning is a bit of pitting on the cooler radiator thing where the o-rings were sitting. Could this be the failure point? I guess the oil was being forced into the coolant at this point. (Thanks for the diagnosis Paddy)

https://i221.photobucket.com/albums/dd227/serendipity_uk/CBR600FR/IMGP4124a.jpg

Is it worth trying to fill the pitting with Araldite or epoxy putty? Or would it be safer to just buy a new part? New o-rings are already on order and I really don’t fancy having this fail again.

Cheers Simon
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2016 CBF1000F - Commuter heaven | 1994 CBR600FR - Awaiting defibrillation

[Paddy Blake]

I would say you could get a shop to machine about 1/4 a mm of both
ends and it would do the trick.

Paddy.

[Phil_P]

I'd second the machine shop suggestion. If you can't find someone to do the work for you, then you might get Araldite/epoxy to work. You will need to degrease to the n'th degree to get it to stick however. Lots of heat and solvent before the sticky stuff. A small butane torch would be good as it will burn out the oil but not be hot enough to risk melting the ali.
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It is not enough to win, others must fail.
Moto Guzzi 1100 Sport Injection '96

[Serendipity]

Thanks for that. Can anyone recommend a good machine shop in the High Wycombe/South Bucks area?

As far as degreasing goes I would normally use isopropyl alcohol (IPA) and I’ve got a little butane/propane torch. However I will go down the more professional route first.

Cheers.
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2016 CBF1000F - Commuter heaven | 1994 CBR600FR - Awaiting defibrillation

[Pete.]

I would glue/tape a couple of sheets of 280-grit wet & dry to a flat surface and lap those marks out using WD40 as a lubricant. Should take less than 10 minutes.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Paddy Blake]

Be sure there is enough space for the dowels that fit into it.

Paddy.