Other Need help with leaking prssure test on 66e at rear seal HELP !!!

feartheride

feartheride

feartheride
Location
St.Catharines,On.Canada
I just got around to pressure testing this xl 800 mtor I rebuilt.

http://www.x-h2o.com/threads/98721-...-xl-800-motor-looking-for-any-tips&highlight=

never had a problem like this before !!
It's leaking badly from rear seals.. At 10 psi it drops quickly to 5 then holds..
I'm starting to second guess if I got the seals in right.. (this can't be happening )..
When
I dissasebled I thought I kept old seals in correct order on old crank but when I went to reassemble, the new seals would just not go in that way..I thought the one with the little nibs on faced nibs toward bearing but it would not line up with grooves in case that way..fom looking at the poor sketch in manual it looked like the one with the nibs was on the outside and nibs faced out and that is the only way the seals would line up with grooves...

New crank and seals..what gives

I should have no trouble splitting the cases and leave top end assembled correct ? nightmare

Might have to come up with different hole to prssure test from as when I remove the pump from yhe pulse line there is still pressure in the bottom end

Any thoughts...I really need this done and out of my way..
 
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Waternut

Waternut

Customizing addict
Location
Macon, GA
Yes you can flip the engine upside down and just pull the bottom half of the case off assuming there is nothing in the flywheel area holding them together that needs to be removed first. I did this to an engine once and it's super easy. I put the engine upside down on my jetski trailer and worked on it that way. Put the pistons in the middle of the cylinders so you don't accidentally pull the crank too far up and pull a piston out of the cylinder.

Might be worth checking the old seals and see if they go in the way you thought they did once it's apart.
 
cattledog

cattledog

EH TEAM RACING
Location
toronto canada
i would not use any wsm part even if it was were for free, there cables are :):):):), i know of 3 people that bought brand new stators for a 701 that did not even work, gaskets are crap, i would bet that they were not made right put oem seals in
 
feartheride

feartheride

feartheride
Location
St.Catharines,On.Canada
So ,the way I see it there is only three possibilities all of which seem unlikely...
The seals are bad
The seals are sitting to close to the end of the shaft..which I noticed on assembly.seemed like the seals were very close to the end of the shaft..
or the guage is reading improperly but highly unlikely because it is leaking at 8 psi and should take much more..
 
Waternut

Waternut

Customizing addict
Location
Macon, GA
If you think your gauge is reading improperly or leaking, dunk the entire engine in the bathtub and watch for bubbles. The bubbles never lie. That's how I find those really hard to find leaks.
 
feartheride

feartheride

feartheride
Location
St.Catharines,On.Canada
Soapy water in a spray bottle.. I know its leaking..
but it holds for 20 min at 5 psi so wondering if guage is off and I have more pressure then I think although I doubt it..
i will try my watcon pressure tester this morning..

It may be just holding the 5 psi at carb side of reeds as I am hooked into pulse line....

would I damage the reeds if I pressure test through spark plug instead or exhaust plate..
Didn't want to have to take out the reeds but may have too, to get a better idea of what is going on.. or just stick something in between reed petal to hold open//
 
Waternut

Waternut

Customizing addict
Location
Macon, GA
Not exactly sure how you are testing. I plug the carb and exhaust opening with test plugs or freeze plugs and I have the reeds and both manifolds installed. Then I add pressure to the pulse line. Once I get to 9-10psi, I close the ball valve going to the hand pump because it'll leak. Air will get through the reeds, they aren't perfectly sealed.
 
feartheride

feartheride

feartheride
Location
St.Catharines,On.Canada
Waternut said:
Not exactly sure how you are testing. I plug the carb and exhaust opening with test plugs or freeze plugs and I have the reeds and both manifolds installed. Then I add pressure to the pulse line. Once I get to 9-10psi, I close the ball valve going to the hand pump because it'll leak. Air will get through the reeds, they aren't perfectly sealed.
Click to expand...

same way except I have steel plates with rubber gasgets to seal on intake side, no intake on 66e and rubber seals between the case and exhaust manifold.. and I don't have a ball valve.Ihave an inline check valae in mine..
And yes the reeds appear to be not letting all the air out after I disconnect so they are getting tight seal..
 
feartheride

feartheride

feartheride
Location
St.Catharines,On.Canada
o.K. checked with other guage pressure is correct...As I previously stated I think the issue is the crank..

the seal is so close to the edge of the shoulder before the threads that at 5 psi it is staying on the surface of the dia. but as I go to 10 psi the seal puffs out to much and hits the micro shampfer on the shoulder..
The seal is actually flush with the shoulder..
This concerned me from the get go

does any one have an assembled 800 motor they can look at and see where the seal sits..
and can anyone confirm with me that the seals can't be put in wrong and line up with the case grooves

This shouldn't surprize me as i have already had pistons that were improperly machined to clear the rod and a renickasilled cyl that had to be replace..

Where are you 66 e800 guys.. need some help here
 

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norcal ex

norcal ex

X-H2
Location
San Jose, CA
the four numbs face outwards which your look like they are. It is hard to diagnose without having the OEM crank seals in. Aftermarket seals already have enough issues....
 
feartheride

feartheride

feartheride
Location
St.Catharines,On.Canada
norcal ex said:
We dont know about the other rear crank seal because that one doesnt have nubs. I highly doubt something is wrong with the crank....
Click to expand...

Well the inner seal can't possibly go in any other way due to where the groove is in the case... I have been second guessing seal position but i am positive the seals can only go in one way....

yea hard to believe the crank is bad but all it takes is for the stub end to be pressed in to far by 250 microns (.010 ") .. I repair nc machines that machine automotive cranks and its more then possible to build a bad crank the ? is does it slip through quality control....
don't get me wrong I would love it to be a bad seal but not likely either....

the following pics show the seals with the inner seal in the opposite way.. can not happen..
 

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feartheride

feartheride

feartheride
Location
St.Catharines,On.Canada
Just thinking about this and the outer seal shouldn't even see pressure from the case as it is for dirt or vaccum as the inner seal seals against pressure from the inside..
so toda I will split the case and install the old seals and see what I get..
 
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