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SV1000 (03-07) Tech Info, advice or questions specific to 2003-2007 model SV1000. Sponsored By: Werks Parts

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Old 10-12-2019, 04:15 PM   #11
snailman153624
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Join Date: Oct 2013
Bikes: '04 SV650
Posts: 1,390
Re: Sucky pushrod seal design

Is it possible you have a pinched or blocked hose/air valve?

Especially when the motor revs up, there are lots of air pressure pulses that can pop seals out if not vented properly.
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Old 10-14-2019, 06:03 PM   #12
China Greg
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Join Date: Oct 2009
Location: Lower Hudson Valley, NY State
Bikes: '06 sv1000s, '98 Bandit 1200 modified
Miles Kms: 30K on SV, 140K on Bandit
Posts: 371
Re: Sucky pushrod seal design

Well, here's the next wrinkle-

I started the motor today and looked at the seal/retainer config I had made; oil seemed to be coming out of one of the sheet-metal screws that I'd used to fasten the seal to the retainer plate.

So I pulled it apart and tried reassembling it.. this time with a previous seal (okay on the outside but a bit stretched in the center hole). I used my home-made nylon spacer behind the seal this time, to hold the seal from moving inwards .. and the fabbed outer retainer, bolted to the case, this time with no screws attaching it, but the plate preventing the seal from moving OUT.
Result:

No leakage.
After ten minutes, (and all the tons of previously spewed oil burning off), the thing sat there and ran with only some light weepage from the seal center hole.

Promising! But I noticed the pushrod end moving...oscillating up and down a little. I put my thumb over the end, and could feel a bit of a ..hmm.. warp vibration...

So I'm wondering if, when I snapped the chain, that the force not only bent the LH steel pushrod, but maybe also the LH aluminum one...and that is causing the oscillation.

So tomorrow I will peel off the left engine cover (hate this job on the SV.. all the oil and coolant out)... and look for any damage to the RH pushrod...as well as the trans bearings, of course... lift up and down on the clutch, sense for clicking in the bearings, etc. Also examine the pushrod thrust bearing.

But,... no leak today! maybe a sign that I don't need to buy a motor!
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Old 10-27-2019, 03:47 PM   #13
China Greg
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Join Date: Oct 2009
Location: Lower Hudson Valley, NY State
Bikes: '06 sv1000s, '98 Bandit 1200 modified
Miles Kms: 30K on SV, 140K on Bandit
Posts: 371
Re: Sucky pushrod seal design

Nailed it! Bike is running leak-free for the first time in two months.

My cut & drilled retainer concept worked, cutting the retainer into two pieces and securing the pushrod seal side of it to the cases by means of a 6mm hole drilled and tapped into the case... but on the first design I added two tiny sheet metal screws.. and oil leaked past one of these.

So I got (yet another) fresh seal and this time installed it with the modded retainer, but no screws. This meant that the seal could GO IN but could not pop OUT. Previously, the seal was twisting its' way out of the bore, (my guess is that the slave cylinder piston got distorted...I replaced it with a FleaBay donor).


So after 500 miles or so all is DRY, Mutha! Wheee-HOO! I'm ridin' SV again!

NOW... if I could just eliminate that tiny steering warble.... I'd be SET
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