CAM SEAL LEAK

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TAPPET COVER LEAKS
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CYLINDER HEAD COVER LEAK

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Throughly cleaned and degreased section of bike I was going to be working on.
Placed engine at TDC compression stroke and removed oil cooler line to the rocker cover.
Did not remove CCT or relieve tension off it. (not sure if I should have but it didn't cause any harm anyway)
Removed top engine mount.
Removed cylinder head cover bolts in order per the manual and placed on a piece of cardboard with holes punched in it in the shape of the cover and placed each bolt as they came off, being careful not to loose any sealing washers, in each hole for safe keeping

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Bit of a tap to cover and it came free. Removed it and inspected. Very little evidence of sealant from factory at all.

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What is unusual is the sealing surface on both components (head and cover) in the common area for these to leak on most DR650s.
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Refer to ER70S-2's photo above that shows corrosponding area... strange.

Anyhow, After a through clean down of the two sealing surfaces and using JBweld Ultimate Grey Gasket Maker and Sealant, a thin line of sealant was applied to the cover only as per the manual. New cam seal inserted with no sealant.

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Reassembled and bolts back in and very lightly snugged up in the order per the manual until sealant began to ooze from the joint. Let sit for about an hour before torquing up the bolts to spec. Reassembled the previously removed bits and left for 24 hours to fully cure.

24 hours later, reset valve clearances, instal new valve adjustment cover seals and torque to spec.

Complete assembly of bike and ride about 100kms. Check for leaks/weeps - All good