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2019 Kodiak 700 Base , New to ATV , Crankcase Leak

310 Views 3 Replies 2 Participants Last post by  Stingray8
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Hi guys! I just got this Kodiak from my boss who's PCS out of the military yesterday and i did know it was leaking and was sold to me cheap. But at first i thought the leak was coming from the bottom screw so i drilled it and Hexa coil it. but noooooooo its squirting out of the crankcase above that. shockingly when i opened the crankcase i saw this "Metal shaved" at the top of the screw area i hexa coiled. How can i fix this? Gasket? Gasket maker? Seal after those both? Thank you so much! I am not so mechanically incline as this is my very first ATV. Thank you! Squirting Oil from Crankcase <<< Heres the video of the crankcase spitting out oil

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Looks like someone probably replaced the stator and they had the entire crankcase (stator) cover off and did a piss-poor job cleaning and reassembling it. Not sure exactly where that gouge is on the crankcase, the two pictures that look the same, but you are probably going to need to order a new crankcase gasket and get some Yamalube Yamabond #4 Adhesive Semi Drying Liquid Gasket and make sure to wait for it to "dry" before adding any oil to the engine. Based upon your pictures and video, I can almost guarantee who ever did that job, also stripped most of those bolts that hold the crankcase cover on, something like 11 bolts or so. Those bolts should only be torqued to 10Nm (7.2 ft lbs) which is not very much and EXTREMELY easy to over tighten and strip the case threads. You might want to be prepared to Heli-Coil all of those. A 3/8" torque wrench is too big and just not accurate for delicate work such as those M6 steel bolts into aluminum case where many don't realize a torque wrench isn't always for making sure it is tight enough, it is there to not OVER tighten. Find yourself a 1/4" torque wrench, like something used on high end bicycles. And then HOPE all that fixes the leak.
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Looks like someone probably replaced the stator and they had the entire crankcase (stator) cover off and did a piss-poor job cleaning and reassembling it. Not sure exactly where that gouge is on the crankcase, the two pictures that look the same, but you are probably going to need to order a new crankcase gasket and get some Yamalube Yamabond #4 Adhesive Semi Drying Liquid Gasket and make sure to wait for it to "dry" before adding any oil to the engine. Based upon your pictures and video, I can almost guarantee who ever did that job, also stripped most of those bolts that hold the crankcase cover on, something like 11 bolts or so. Those bolts should only be torqued to 10Nm (7.2 ft lbs) which is not very much and EXTREMELY easy to over tighten and strip the case threads. You might want to be prepared to Heli-Coil all of those. A 3/8" torque wrench is too big and just not accurate for delicate work such as those M6 steel bolts into aluminum case where many don't realize a torque wrench isn't always for making sure it is tight enough, it is there to not OVER tighten. Find yourself a 1/4" torque wrench, like something used on high end bicycles. And then HOPE all that fixes the leak.
Funny enough you nailed it on what happen he was working on stator. Now after he put everything back he don’t know why it’s “leaking” I really appreciate this! I will follow what you said. And prolly use JB weld first to fill the gap of the missing metal. Thank you! Will update the thread next week
Update #1 jb welded the gap! Looks great so far, waiting for 24 hours to fully dry and will sand. Waiting for my gasket , gasket maker to arrive
Wood Gas Automotive tire Circle Tints and shades
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