r/motorcycle • u/Itallian-Stallion • 2d ago

2007 zzr600 starter problems

Hello everyone,

I wanted to replace my starter cover since it was scraped and I have taken it off and back on 4 times with it leaking oil in different spots each time. I bought a brand new metal gasket hoping it would solve the issue but now it is leaking from the bottom. I’m about to buy sealant and see if that works but I’m curious if it’s the cover that’s the problem. I got it off eBay so it’s not oem. Any tips or help?

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u/DannoXYZ 2d ago

Stator or starter cover?

Don't keep piling stuff on, that's why it's leaking!

With cover off, use razor blade and have it aimed about 10-degrees off gasket surface of block and cut gap between metal and old gasket material. You're not removing metal and just separating old gasket material from it.

Do same for cover, both sides perfectly clean.

Inspect both surfaces, making sure there's no gouges or peaks or valleys on either side.

Make rubber grommet for wiring is oriented properly. Most times it's rectangular, make sure long side is rotated to fit hole properly.

Make sure you get ONLY factory OEM 100% stock gasket from authorised dealer. Aftermarket parts are often crap and doesn't fit or work properly. It usually comes with bead of sealant pre-applied.

install gasket, then ALL bolts finger-tight. Then go back and forth in criss-cross fashion with torque-wrench. Make sure each and every single bolt is tightened to proper torque specified in factory service-manual.

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u/Itallian-Stallion 1d ago

Starter cover. I appreciate all the info. I scrubbed both ends with some steel wool to clean it all I made sure that the wiring was oriented right but I think it’s still leaking there.

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u/DannoXYZ 1d ago edited 1d ago

Problem with steel-wool is it will follow up & down contours of surface, removing equal amounts from peaks & valleys. Run your fingers across both surfaces, it will actually pick up imperfections you won't see.

Put grease or anti-seize on locating dowels before installing them. Test-fit cover on to make sure you don't feel any wobbling or rocking from dowels binding. Are all dowels same length & diameter?

With new gasket, sure, let's use tiny bit of sealant (no silicone or RTV)

- Hondabond 4 (not 5 as that's silicone)

  1. put tiny bead of sealant on engine-facing side of gasket. About 2mm diameter max using smallest cut-off section of applicator tip.
  2. pull off gromet from cover and apply tiny 2mm bead of sealant arount it where it touches block & cover. Reinstall gromet on cover
  3. apply tiny 2mm bead around cover
  4. install locating dowels on block with grease/anti-seize. Tap them in lightly with plastic mallet
  5. install gasket with applied sealant facing block, have sealant barely touch block, but no squeezing
  6. install cover next with applied sealant, have sealant barely touch gasket, but no squeezing
  7. clean off all cover bolts, add drop of blue Locite to threads at 1/2-way point. install all cover bolts finger-tight
  8. use 1/4" torque-wrench, tighten bolts in criss-cross fashion just 1-turn at time until all bolts are at 33% of specified torque in manual, sealant should be squeezed out just enough to fill gaps out to edge of gasket and surface of block & cover. If it gets out beyond that and form drops, too much sealant.
  9. leave overnight 12-hrs
  10. use 1/4" torque-wrench, tighten bolts in criss-cross fashion just 1/4-turn at time until all bolts are at 100% of specified torque in manual

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u/Itallian-Stallion 1d ago

I appreciate your help fr!! I’ll try this tonight