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Old 02-13-2013, 03:39 AM   #1
Britome OP
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Oil cooler leak

Took my first test ride on a 2006GSA that I'm rebuilding. I had a lot of oil leaking freely by the hose clamp. I replaced it but the leak persisted. Not at idling but at higher rpms. I took the oilc cooler off because I thought it was leaking out of a hole on the top. On further inspection, that hole is a factory hole mirrored by one on the other side. There are no visible punctures on the unit.

Now I'm confused. I've ordered a used one from a guy in England. It will take 10 days to get here. I'm itchy to get this thing running again. Any chance I misdiagnosed? Should I put it back on and run high rpms in the garage to inspect further? Anyone have any experience with this?
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Old 02-13-2013, 06:20 AM   #2
Dan Căta
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Where is it leaking exactly? At the metal part or at the pipe part?

Dan.
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Old 02-13-2013, 06:23 AM   #3
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Oil was everywhere. I couldn't tell. I though it was from the hole on the top but then noticed that was from the factory and matched one on the other side.
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Old 02-13-2013, 10:14 AM   #4
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Britome,

mine leaked a couple of years back, I kept finding oil residue around the key switch, finally noticed the oil cooler leak one day while riding in some very dusty conditions, cleaned , and talc powdered.
couldnt find the leak, I removed it, used degreaser, and a wire brush to clean it all up, had thoughts of brazing it if I could find the leak... never could find it, I know where it was seeping from, but must have been a tiny hairline crack that my eye ( 20/20 vision) could not detect.

I simply replaced it with a used one, and the leak went away.

the oil cooler on my bike was made in austria by KTM by the way.
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Old 02-13-2013, 10:17 AM   #5
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Britome,

mine leaked a couple of years back, I kept finding oil residue around the key switch, finally noticed the oil cooler leak one day while riding in some very dusty conditions, cleaned , and talc powdered.
couldnt find the leak, I removed it, used degreaser, and a wire brush to clean it all up, had thoughts of brazing it if I could find the leak... never could find it, I know where it was seeping from, but must have been a tiny hairline crack that my eye ( 20/20 vision) could not detect.

I simply replaced it with a used one, and the leak went away.

the oil cooler on my bike was made in austria by KTM by the way.
Thanx so much for the insight. I was thinking through, going through a similar process that you did while I wait for my used oil cooler to be shipped from England but you may have just talked me out of it.
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Old 02-13-2013, 10:42 AM   #6
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Could you take the oil cooler off, attach some hoses and pump it with air from a tire pump? Check for a leak, dip it in water or oil look for air bubbles. Just a thought.
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Old 02-13-2013, 10:47 AM   #7
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Could you take the oil cooler off, attach some hoses and pump it with air from a tire pump? Check for a leak, dip it in water or oil look for air bubbles. Just a thought.
Yes I could, but I'm unsure if even after possibly locating the hole, if I would want to fix it and trust it on my next trip 1,000 miles away in the middle of nowhere.
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Old 02-13-2013, 11:21 AM   #8
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Good point. Radiator shops fix that type of cooler I think. 10 days and you'll have your new one.
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Old 02-13-2013, 11:59 AM   #9
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Radiator shop...quit screwing around and have a pro fix it.
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Old 02-13-2013, 05:13 PM   #10
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So I blew air into the unit and here was the obvious breach...



It looks like something is damaged underneath this plate.
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Old 02-13-2013, 06:15 PM   #11
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OK, now what?
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Old 02-13-2013, 06:17 PM   #12
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OK, now what?
I try the radiator shop
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Old 02-14-2013, 08:23 AM   #13
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You get better results when you tell the hole story. Story of a totaled 2006 GSA

Rebuilding after an accident then yes replace it. This post is the only oil cooler leak I remember reading about in the past 10 years.

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Old 02-14-2013, 08:56 AM   #14
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You get better results when you tell the hole story. Story of a totaled 2006 GSA

Rebuilding after an accident then yes replace it. This post is the only oil cooler leak I remember reading about in the past 10 years.

True. Sorry. However, I just got it welded and will check it out.
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Old 02-14-2013, 10:45 AM   #15
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There was a guy stuck in Mexico asking for help, his bike won't run. He gets 5 pages of responses before it comes out he rebuilt his stator on his DR650 and that is his problem.

Sometimes it takes several posts just to find out what bike guys are talking about. Just saying.

Did you weld it or have a radiator shop do it?
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