pbekkerh wrote:Considering your previous "case joining" history, are you sure the cases seal in the middle

The left side of the crank case holds 8psi 100% for atleast 10 minutes with no noticeable drop. Its definately not a problem with the crankcase joint since i re-made it with Threebond 1207B.

The crank case joint was good when the engine was first put back together in 2006 and the engine ran very strongly. Its only recently that i've been trying to get the bike back out on track since moving to NZ and problems have arisen. After a couple of little test rides i found the front of the engine covered in sticky dirt and then noticed a trail of fuel leaking from behind the flywheel. I decided to do a leak down test and that's when i found the leak on the crank case joint. The flywheel side crank seal was also letting air past.

It seems that over time fuel has dissolved its way through the Blue Hylomar in the crankcase joint and the crank seals have been damaged by the weight of the crank during the bike's storage.

Since the rebuild a couple of weeks ago all external leaks have been cured. I'm just left with this curious cross leakage which only lets air pass from right to left through the center seal (presumably).
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