AAAAAARRRGGGGHHHH!!!!! Frustrated with Dead Peg!

[stisma]

.... What temperature does the fan usually kick in at?
Cheers,

Ste

The fan should kick-in between 90-95*C.
Poor connection on the thermo-switch can alter the setting.

[SJL]

The fan should kick-in between 90-95*C.
Poor connection on the thermo-switch can alter the setting.

Thanks, will replace the connectors with new ones!

[SJL]

New NGK Iridium plug fitted, exhaust tightened up (and this time loctite used on exhaust bolts), tested all running ok.

Started it up again 8 hours later, and the oil filter cover seal popped out and spat its oil out AGAIN!

I have used 10w 40 Magnatec oil, BMW filter, replaced the seal twice and replaced the oil filter cover.

Any ideas??????

Cheers,

Ste

[stisma]

.... and the oil filter cover seal popped out and spat its oil out AGAIN!

I have used 10w 40 Magnatec oil, BMW filter, replaced the seal twice and replaced the oil filter cover.

Any ideas??????

Cheers,

Ste

I wonder if the oil system, which is rather complex on this Rotax, needs purging?????
The manual says it needs purging (air removal) if the engine has been overhauled or such.
I suppose the air-pocket in the oil could possible cause the above problem when the oil/engine temp heats it up.
Can this be? Anyone? (it happens with the coolant having air-pockets)

Is it possible that the engine was worked on or it simply needs this famous purging?

This would be my next step I guess.

...food for thought.....
I've seen people cranking the engine after the engine oil was drained, saying it will get rid of remaining oil in the engine.
Such doing can cause......issues. Not saying this was done on your bike....just blabing here.

[SJL]

I wonder if the oil system, which is rather complex on this Rotax, needs purging?????
The manual says it needs purging (air removal) if the engine has been overhauled or such.
I suppose the air-pocket in the oil could possible cause the above problem when the oil/engine temp heats it up.
Can this be? Anyone? (it happens with the coolant having air-pockets)

Is it possible that the engine was worked on or it simply needs this famous purging?

This would be my next step I guess.

...food for thought.....
I've seen people cranking the engine after the engine oil was drained, saying it will get rid of remaining oil in the engine.
Such doing can cause......issues. Not saying this was done on your bike....just blabing here.

Blabbing always welcome.... I usually find it jogs the memory!

Now how do I purge the system? I have had the head off not long ago so maybe.... Just maybe......

Cheers,

Ste

[stisma]

......Now how do I purge the system? I have had the head off not long ago so maybe.... Just maybe......

Cheers,

Ste

It is the best if the engine is more than just warm, not hot.
You want would be air to expand and oil to flow easy.
Double rubber gloves and than some, the oil cover and filter will be hot.
Remove the oil filter, make sure planty of oil is in the oil tank, add to the max line.
Loosen the screw behind the oil filter, just loosen, sit and sip couple of beers.
Sometimes the oil starts coming out on its own from behind the screw and or filter opening,
takes some time, if not....remove the spark plug, pick a gear and turn the rear wheel, proper direction.
Cranking the engine with very short bursts is the last option.
I did it twice just by waiting for half an hour or so, without turning or cranking and once without even loosening the screw.
(the bleed screw tends to seize-up....heat and more heat helps in loosening it)
But like I said, I did it once without loosening the screw, just by removing the filter and waiting for an hour.

Tighten the screw, oil-filter on, new O-Ring on the cover, check oil level in the tank, ride, wait, check oil level again.
Very easy job.
Also, make sure the oil breather tube is clear and no kinks and twists.

[robg]

The service manual says to loosen the screw and position the kill switch to the "off" position, then turn it over until oil flows.
After the head gasket replacement, if I remember correctly, I tried to do this. But I'm sure the valve screw would not budge. But oil seemed to start coming out! I'm due to check the torque on the head bolts soon, so I am going to try warming it up as you suggested stisma. Also noticed that I have a small oil leak from the filter cover. Only started recently.

[SJL]

Thanks fellas, will let you know how I get on! Not sure if I will be able to do it today.

Cheers,

Ste

[SJL]

Thanks fellas, will let you know how I get on! Not sure if I will be able to do it today.

Cheers,

Ste

Now, before I get my spanners out.... Does anyone have a photo or diagram of what it should be like in the oil filter housing. If I remember rightly, there is a large flathead screw in the bottom of the housing pointing towards the engine, and there is a round rubber seal in the middle of the housing.

Is the flat head screw the one to remove? Is it worth borrowing an impact driver?

Many Thanks,

Ste

[stisma]

I don't have a pic, but yes that is the screw.
No impact driver!!!
If you can not get it loose....see my above post....... it just might purge itself.

More on your issue......
If you look in the Rotax 655 Workshop Manual,
go to page 51....Oil Pressure Regulating Valve.
This also can be the culprit for the issue with blown O-Ring.

[SJL]

OK, after some searching online and for the the benefit of anyone else with the same problem....

Oil filter diagram


Oil pressure regulating valve screw. (Ignore the right hand picture)


Now time to get the spanners out!

Ste

[SJL]

Sorted...... After messing about.... There was a rubber disc in the oil filter housing in the centre hole which looked like the previous owner had allowed an oil filter to disintegrate before replacing it, and also, when I have replaced the oil filter I have replaced the oil filter cover O ring with an Aprilia genuine part which is 2.5mm thick, which was still weeping oil; then I replaced this with a BMW oil filter O ring (part number 11417654013) which is 2.62mm thick - this has sorted it. I have taken it for a 40 mile run and it has not (yet) leaked! I hope it is ok now.....

Cheers,

Ste

[stisma]

Nice!!!

[madoldbird]

Result

[SJL]

And now....... Bike "missing" a revolution quite a lot while doing 50mph +, especially when using anything electrical. It happened quite suddenly each time, so suddenly the bike lurched and almost threw me off! Now it has stalled and will not re-start - unless I remove seat / air filter and blast eze start into the carbs - but will not keep running. I have ordered a new starter solenoid and a replacement coil and HT cap / lead to try next.......