If it's not leaking from the Exhaust valve inspection/adjustment cover 0-ring,
then there may be a crack in the cam cover, or cyl head ?

New O-ring, have inspected for crack but cant see anything.

Hi , Before you take cover off again try taking the leaking bolt out blast it and its hole out with brakclean and compressed air smear the bolt in grey silicon . l use a three bond product it works so well. l fit water pumps rocker covers etc with great sucsess ! l dont have the numbers of the tube at home. lf sealing the bolt dosn,t work and you need to try the rocker cover again try a light sand with fine sandpaper and brakcleen grey silicon dont do the bolts up tight (maybe 1 Nm if that ),and the next day talk them down in sec-wince starting from the center of the head outwards and the let it sit for another day. Check your engine breather is not blocked and l hope l am not trying to tell you how to suck eggs :smartass: But I do it for a living and meet lots of clever people that dont have a clue how to fix motors :( . Hope this helps you !
I just striped my XT600e down the 5th gears are gone :thumbdown: I miss it allready :mchappy:Still trying to find some gears

Thanks i will try the bolt trick, and i think it would be to prefer not doing the 10nm at first so thats my next step. And i use 2000 wet paper and silicon remover every time. Breather hose is open. I buy the Permatex ultrablue next time, then i tried them all hehe.

Hope you get your gear fixed soon, always fun riding these bikes:scooter:

Hi ,the stuff I use is threebond 1215 its not cheep but it WORKs and l like to do the job once! ! :thumbup1: I,m riding my GSXR1100 in the meantime and its great in a straight line ,but there is nothing like a XT600 in the tight windy (FUN) roads !!:funmeterno: Good luck

Bought the Ultra blue from Permatex today, and actually it says on the package that you only should tighten the screws til you see bond coming out and then wait for an hour before do the full tightening. Make sense to me, strange no others of the bond i bought said the same. So lets hope this one will be the last, i think its 7 or 8 now...Looking forward to it, its real fun removing all the bond:thumbup1:

Fingers crossed it works this time! I may give mine another go if you are sucessful xtrock.

Bill

Hehe i thought so, yes it not worth all the time and work if its leaking first trip on the road. I let you know excactly what i did if it seals up, if it leaks i recomend a rag around top of engine next years HAHA:D

Done the seal again, after a long trip yesterday it was to much oil around the top so just had to do it. A couple of things that can be useful for others: When you have taken the headcover off, suck up some of the oil underneath the camshaft. Or else when you press camshaft down again oil will come up and maybe out on the new seal. Same is with the screw holes, if there already have been oil down in the holes you need to get it out. Use a screw and just screw it in, oil will come up. Other than that set of alot time for the clean up, it suck bigtime...I rather be out in the night riding in the sun now, well lets hope this was the last time for a while doing the job or i will order a brand new engine from factory:clap:

Same shit different day... Leaking from same spot again so its not the seal brand thats the problem, iam thinking its maybe not straigt and sealent cant fill this. I was just thinking wouldnt it be possible to get the feeler gauge in if the cover is not straight anymore, maybe if i had checked when surface is clean and monted bac without sealent just for checking gap where its leaking?

Update on the problem!

http://www.horizonsunlimited.com/hub...w-models-77110

A little update, last days i have been doing about 500km on good and rough roads. I did the seal with epoxy metal and still no leak, so iam happy riding and enjoying my great XT:scooter:

Ok, season ended here and i removed headcover for a better fix. If anyone have experience welding maybe check this out and give some reply if its possible to fix. Is it possible to get the welding device inside here and how about that plug outside, best welding that hole up? If i dont weld, can i use the JB weld inside the cover?


http://s9.postimg.org/4drqd1gr3/DSC_0118.jpg


http://s22.postimg.org/m8vz1bopd/DSC_0119.jpg

Not easy to find complete head assembly, and you never know if they have ctack too. In the beginning its impossible to see the crack under the rocker arm.

Plus a person really needs to get the matching head along with it so that also needs to be in good shape. I wouldn't just replace the cover unless the cam bores are checked out for alignment to the old head.

otherwise I can do the work on it and could fix one up, maybe for a trade ? E-start transmission maybe??? just saying.

THanks for the offer, but shipping is to expensive from this country. Iam better off trying to fix this here, iam taking the cover with me and ask some people. If they cant weld it all inside consider the small space it would help just to get some spot weld to stop the crack going further, outside they can do a weld to give it more strength and the rest i fix with JB weld.