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Premium Member
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24,892 Posts
Often they get over-tigthend and warped. I belive rifleman found that slightly shortening the metal spacers helps. Later model TLS's and TLR's use a different clutch cover that is said to be more leak resistant. All models use an o-ring for sealing, later o-rings are bigger IIRC. You can also seal it up with rtv type stuff, just take the o-ring out, smear a little in the grove, put the o-ring back in, smear a bit on the outside of the o-ring and re-install. Don't over do it as you don't want bits of rtv oozing out into the crankcase and clogging stuff up.

If you leave the bike on the side stand you can take the clutch cover off without loosing much if any oil.

have fun
 

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Premium Member
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7,697 Posts
If it's an original 1997 TLS cover, just throw it in the trash and get any later cover. The later ones have metal bolt-hole insterts with a shoulder, and they have an o-ring with a larger cross-section. The early ones are very susceptible to plastic distortion and the bolt-hole sleeve inserts popping loose if ever over-tightened or used with aftermarket bolts without hte very large sholders of the stock bolts. Once the sleeves pop free and the plastic is compressed, the sleeves actually prevent the cover from tighetning up correctly, and the early o-ring wasn't very forgiving.

Make your life easy and just get a more recent cover. They fixed it for '98 and any other cover will fit; get one and a new o-ring any you'll probably never need even another o-ring again. Don't got for the RTV except as a very temporary fix after a lot of cleaning with good solvents.

Check out the Vandriver billet cover if you can afford it.
 

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Scooter hottie chauffeur
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4,663 Posts
the 97S covers are fairly notorious.

here is how to fix them.

http://www.tlzone.net/forums/showthread.php?t=66337&highlight=97S+clutch+cover+leak

I just put a touch of RTV in the O-ring groove, and then put in the O-ring in and seat it in the RTV.

then bolt it up, put large washers on as you put the bolts in, so that you spread the pressure out over larger amount of plastic.

97S covers can be sealed, just need to work at it.
 
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