GT550 Transmission leaking Oil

[garyscc]

hi, I'm trying to get the oil level to be reliable in the GT550. I read some previous threads that say there is a oil level screw/plug. Can someone post a picture of where its located? Also, I added some 10w40 (I now realize 20x50 is better) and it came out immediately from the bottom of the motorcycle, at a 'seam', almost dead center on the bottom of transmission.

I'd also like to know if you guys recommend an ATV silicone or JB weld to patch up the leak. I'd rather not pull the entire engine just to fix this leak, if its possible. Also, I rode the bike about 10 miles with it running low on transmission oil - so I was curious if I could have done damage to transmission during that time.

[Alan H]

See my other post. But;
DON'T run with low transmission oil.
Use the correct amount of the correct oil.
Take the kickstart off, take the brake pedal off, lower the silencers and take off the clutch cover.
CLEAN the faces of the clutch casing and the crankcases carefully and get all the crap off.
Fit a proper gasket - no silicone or anything else. It turns to sh1t and makes a helluva mess if you use too much.
Put 1500cc (or 3.17 US pints) of a good quality 20w40, or 20w50 oil in there.
Check for leaks.
Refit exhausts, brake pedal and kickstart properly.

If you don't have a parts or service manual, look on ebay and get one very soon - they are invaluable.

[garyscc]

thanks for the help. That was awesome. I have the Clymers repair manual for the GT550, but found it to be useless for diagnosing or checking fluid levels. I suppose it may help for following your instruction. if you know of a better repair manual let me know.

[yeadon_m]

Gary,
+1 on what Alan says. If it leaks right out of the bottom of the right side engine cover (clutch cover) along the seam running front to back of the engine, then you may have no oil whatever in the gearbox and you will destroy it if you ride it.
If the gasket faces on the right side of the crankcase and the inside edge of the clutch cover are clean and undamaged, then a new gasket, lightly oiled/greased only, followed by evenly screwing on the cover again, will sort it. If it still leaks, someone has narfed up one or both faces and thats a different matter.
Good luck!
Mike

[Coyote]

The 'over fill' plug is on the lower right side. Just ahead of the kick starter shaft and slightly above. It is easy to recognize. It's a small hex head bolt that has a phillips slot a well. You can't miss it. It's the only bolt like it.
You need to inspect things thoroughly --- after a good cleaning. Oil drips from the bottom because it's the lowest point on the bike. What I am trying to say is, it will drip from the bottom no matter where it's leaking. Take out that 'over fill" bolt and make sure you tranny is not over filled. If it is, it will blow oil out the breather pipe. The breather pipe s located just rear of the oil pump under the oil pump cover.

[garyscc]

ok, after further review...I removed the outer cover that exposed the clutch cable. I then added a quart of 10w40 so I could watch the oil leak - and it now appears the leak is coming from the bottom of the cover, on the left side of bike. I tried to upload a photo but it said 'sorry, the board attachment quota has been reached'.

I removed the Phillips bolt (that is behind the kickstart lever) and then poured the entire quart of oil. I made sure the hole was not plugged. No oil at all came out of the hole. It all came out (slowly, but faster than a drip) out of the cover as noted above.

[Alan H]

ok, after further review...I removed the outer cover that exposed the clutch cable. I then added a quart of 10w40 so I could watch the oil leak - and it now appears the leak is coming from the bottom of the cover, on the left side of bike. I tried to upload a photo but it said 'sorry, the board attachment quota has been reached'.

I removed the Phillips bolt (that is behind the kickstart lever) and then poured the entire quart of oil. I made sure the hole was not plugged. No oil at all came out of the hole. It all came out (slowly, but faster than a drip) out of the cover as noted above.

You're losing me with this one. Are you sure you mean the left side? The clutch is on the right and there isn't any oil on the left.
If you have taken the rear cover off the left side, that will give access to the clutch release mechanism when the cable is operated. This is held by three small countersunk studs (x point screwdriver heads) if you take this off carefully - noting how it fits, there is a gasket behind it, then a dust seal and an oil seal behind that where the clutch pushrod comes through. Is the oil coming along the clutch pushrod? maybe the gasket, or seal(s) leak or if you take out the pushrod (it goes back the same way, not turned end for end) is the pushrod scored or grooved?

Have a look here http://www.alpha-sports.com/suzuki_parts.htm" onclick="window.open(this.href);return false; find the year of your bike, then the model, then 'clutch'. A breakdown of the parts is shown with them itemised.

[yeadon_m]

If you really are pouring it into the top hole in the right hand cover (as you should) and it doesn't come out of that overflow on the side of the right cover, but comes out of the left side, under the clutch lifter / engine sprocket area, you either have a cracked crankcase (not good, engine out job at minimum) or a massive oil seal leak (may be fixable in situ, need more info as Alan describes) from gear position indicator switch (wires on it, two screws, O-ring under), clutch pushrod seal (obvious) or behind the engine sprocket.

If I'm following you, clean the hell out of the area of the leak and do your test again while peering around, if you can stand the mess

Good luck!
Mike

[Alan H]

Of course, I forgot the gear indicator thingy with it's pissy seals.
I'm just thinking J/K.
Silly me!!!

[Coyote]

Left and right are as you are sitting on the bike facing forward. Zero oil should be coming from the left side. EVER. If it is, you have one or more bad seals.

[garyscc]

Yes, sitting on the bike - on the right I filled oil into the black cap where the transmission says 1500cc. I removed the Phillips plug behind the kickstart lever. then, on the left, where I shift gears with my left foot, oil is seeping out from the clutch cable cover towards the bottom. I would upload a photo but the system says our quota has been reached.

[Alan H]

I think that looks like you need to remove the next casing (which is covering the drive sprocket.)
Just remove the gear lever and take out the studs that hold the cover and it should come straight off.
If not, you may need to slacken the rear footrest that holds the silencers on that side so they can drop a bit and allow the casing to clear.
I think the favourite will be the seal behind the clutch mechanism, but you’ll be able to see better when the inner cover is off.
You shouldn’t lose any oil with this. You can take the clutch operating rod out to check it isn't scored or grooved - it MUST go back the same way.
Take pictures before you undo anything so that you can put it back the same!

[garyscc]

I took the clutch cover off and found the leak to be from the clutch rod seal, the circulsr black thing. Is thre a trick to get the old one out?

[Alan H]

Pull the rod out, put a thin screwdriver in the hole and gently prize the little sod out. New one should press in. Make sure it's the right way (flat side out IIRC).

[garyscc]

I pulled the rod out, then removed the seal. There seems to be a circular frame in side there. Is that replaceable? It has a few gaps here and there. Should I only order the rubber seal portion?