Left the K sit all winter and did a bit of work on the Guzzi instead, but mostly just mourned the crappy weather in central Pennsylvania (still mourning).  I'm getting reinvigorated to finish this project and get the old girl back on the road.  So, today I drained the oil so I can address a leak.

I did the whole top end (er, left side end) in the fall (an effort to address smokiness).  Upon reassembly, I noted that there was a bit of an offset between the engine case and the front cover -- not much, maybe a fingernail's thickness.  Despite a liberal spreading of ultra black, I ended up with an oil leak -- probably several drops a day -- apparently right where that offset is, below the timing chain.



Now, admittedly, I rushed and tightened down the case cover before letting the ultra black cure a bit.  So, the questions:  Is this gap anything to worry about?  Should I just give it another go with the ultra black and allow proper time for cure before tightening down the cover, or do I need to do something more involved, like filing?

Cheers,

Frey

The gap is just how it is made and the sealant you applied is what is required.  However the manual says to apply the bolts to the correct torque values as this avoids distorting the seal.  

However, looking at the photo, the bolt to the left of the indicated area looks to be loose.  Could this be the problem?

FreyZI wrote:Despite a liberal spreading of ultra black, I ended up with an oil leak -- probably several drops a day -- apparently right where that offset is, below the timing chain.  . . .allow proper time for cure before tightening down the cover . . .

Curing isn't the problem. If the surface is not perfectly free of oil, you'll have problems. Did you reuse the old gasket?

Like TacKler, I was wonder what was happening with that screw, too.

A trick we use in the boatyard is to tighten down on sealant in two stages.

Put the sealant on the surface you want to seal and then assemble, tighten the fasteners only enough to get a bit of sealant to squeeze out all the way around the joint, then stop.

Let the sealant cure for at least a day, longer if possible, then tighten to the proper torque.

What you have done is used the sealant to form a thick gasket that is compressed when it has hardened enough so that it doesn't all squeeze out.

The crankcase end cover probably has been put on incorrectly which makes the other end sit out a bit the best way is to remove the crankcase cover then position the front cover so the ends are flush then once the front cover is tight the crankcase cover and cam covers can be put on without that uneven surface. Just a very small dab of sealant then tighten the cover bolts finger tight, let the sealant cure the tension the cover bolts to 8-10ft/lb.

Indeed that bolt was loose.  Another duh moment in this project.  I'll try re-aligning the timing chain cover before putting the valve cover back on.  So, what's the best way to get the old ultra black and the oil off the gasket so I can get a good seal?

Careful scraping with razor blade to get the large portions off being very careful not to gouge or scratch the surface. Then follow that with a cloth wiping with acetone. You want to remove all remnants of old sealant so that will take time and effort. Don't be tempted to rush the job and use abrasive scrubs.

robmack wrote:Careful scraping with  razor blade to get the large portions off being very careful not to gouge or scratch the surface. Then follow that with a cloth wiping with acetone.  You want to remove all remnants of old sealant so that will take time and effort.  Don't be tempted to rush the job and use abrasive scrubs.

Carefully cleaned.

Questions: Per Haynes manual, "Apply smear of sealant to stick in cover groove."  Is there a sealant that's easily removed the next time I have the cover off?  When they say, a "smear", what exactly is that?  Is it really necessary?

FreyZI wrote: When they say, a "smear", what exactly is that?  Is it really necessary?

It's a smidge that's been spread out by downward and lateral pressure. As far as being really necessary, don't do it and let me know. I'm a slave to instructions.