Suzuki Savage (Boulevard S40) Oil Leak Fix

[@brucebenioff]

This is a real good video, my s40 ( 2007, 19k mi.) has been leaking oil for 2 years, just a small amount but it's gotten worse. So my head cover is off and today I'll seal that plastic cap and around the top as done in this video. Then I'll post the results here in a few days. And a big thank you for including the compression release!

[@brucebenioff]

It didn't work, so I bought that head plug and did it all over again. Still leaks. pouring out at the exhaust. I'm wondering if I have a cracked head? Also considering JB welding that plug from hell. and using grey instead of red sealer.

[@kxnrxd4908]

My recommendation (if you haven’t done this process), would be to thoroughly clean off all the oil on the cooling fins. From there, let your bike idle for a while or maybe take it out for a short ride. It’s considerably easier to see exactly where the oil is coming from when your engine is entirely clean. There is a stud in the cavity below the exhaust header that is also a common leaking point. If you can track your leak to there instead of the top of your head, you may make some progress. Sorry my video wasn’t more suitable to your needs! Keep the rubber side down brother

[@davidlewis7603]

@@brucebenioff kzbin.info/www/bejne/rJm2g554ir6ioJY

[@lmnt02]

As a mechanic I suggest you do not use so much RTV. If you use more than necessary it will break off after a couple of heat cycles and end up somewhere else clogging your oil passages which will starve your engine of oil. Resulting in catastrophic engine failure. Some idiot did that with the valve cover gaskets on my Mustang and the pieces ended up in the cooling jackets which caused my head gaskets the blow.

[@jlrutube1312]

This is very good advise. I was thinking the exact same thing.

[@rocxylemmon8535]

Just like to much grease can be bad as well on bearings or any type of joints.

[@tartredarrow]

Just dont use it at all. I only use it in special places. Certain gasket corners. Certain oil pans. Grommets. Using it on an entire sealing surface is just a heinous nightmare for the the next time you're in there.

[@WE.R.NOT.OK.W.U.TRMP_GTFO]

It's a good practice to finish tightening any screws with a handheld screwdriver, just to keep from accidentally stripping the heads, or adding metal particles in places you don't want them, he's pretty safe in this situation, but it's a good practice. I generally set a soft clutch on the driver, then torque by hand, saves time, saves threads. Good video, I hope it worked out!

[@kxnrxd4908]

driver was clutched soft, appreciate the concern!

[@steve062989]

Thanks for posting this! I just picked up one of these bikes cheap and I need to do this :-)

[@tiebass]

Hello from Brazil! i am have having the same problem Nice video, ty

[@PhilHewkin]

My 2014 s40 has been repaired 3 times by the dealership I bought it from. They no longer sell/repair suzuki. I went to the local HONDA retailler for oil leak repair #4. I have almost $2000 cdn in oil leak repairs. I wish I saw your vid first. I am thoroughly sick of oil leaks. I maybe got 150 miles on the 3rd repair before it leaked again. The HONDA shop will probably charge me $700 because they said they had to remove the engine from the bike to do a proper repair. I sure could have done it myself after watching your vid.

[@kxnrxd4908]

I’m sorry to hear that Phil. These bikes are notorious for leaks, no doubt. If I ever start leaking from the plug again, I will definitely look at the 3rd party threaded aluminum plugs designed to completely stop this problem. Safe riding!

[@PhilHewkin]

@@kxnrxd4908 it was $1030 oo repair total. they said they had to remove the engine from the frame. the upside, everything is working perfectly now and no leaks.

[@kxnrxd4908]

@@PhilHewkin keep your receipts haha! hopefully your issue is fixed though in all seriousness!

[@brucebenioff]

So after 2 times using permatex red and it leaked after a couple of weeks. Has anyone tried a better gasket maker with success?

[@PhilHewkin]

@@brucebenioff I have a theory. Check your air filter. If you can not. See sunlight through it, it is plugged up, and needs replacement. I suspect that the engine is pulling oil into the cylinder, and burning it as well as pushing it out the head. I have seen many cars and trucks do the same, owner thinks engine is pooched, changes air filter, engine runs as new, no more oil leak or burn.

[@michaelelse9328]

💥 S 💨 A 💨 V 💨 A 💨 G 💨 E 💥👍🏻☮️ In my opinion a great video about this problem! 👌🏻 Best wishes from Germany! 🤞🏻 👍🏻🕊☮️

[@JavierTreminio-b3t]

Nice video, do you know the name of the retainer you changed?

[@BahrsFishingFrenzy]

Keep this shit up man! Helped a lot

[@kxnrxd4908]

Thank you! Nothing more frustrating than going to KZbin for help and finding no results… trying to fill those gaps anytime I can contribute. Safe riding man!

[@bhess93]

Great video man. 🙂

[@kxnrxd4908]

Thank you very much for the appreciation!

[@michaeldavidson1146]

Thanks for sharing!

[@peterpiekarski4910]

O no! You forgot to put back and but and bolt to hold down the beauty cover (that nut and bot also holds that cover of the valve cover

[@someguitarguy.]

Nice vid and bike. I have a 2006 which may be starting to seep at around 10k miles, How many miles on yours? Probably wanna consider swapping the OEM petcock as it will fail. Best advice: Run pure gas (no E10). Ever. TWD

[@kxnrxd4908]

23,000+

[@brucebenioff]

yeah my oem petcock failed at 10k.

[@garrettrast2953]

I have a ton of oil in the "bowl" area where the spark plug sits. I also noticed some oil leakage around the valve cover plate. Does this sound like it could be the same problem as yours? Also, do you know if that cap has a specific name?

[@kxnrxd4908]

Sounds very likely in my opinion. If you haven’t yet, clean the entire engine and take it out for a ride. If you can see for sure that the oil is coming from the top, I can almost guarantee that’s your issue. In theory, a leak like that would indicate leaking from the valve cover (on my bike there wasn’t even a gasket). I also don’t know the specific name for the cap, but it’s well-documented issue. Maybe look into the threaded conversion. Thanks for watching! Hope this helps.

[@garrettrast2953]

@@kxnrxd4908 yep, definitely a big help mate! You have the only video about this on KZbin. Atleast for now I have a direction to follow. I hate taking my bike into the shop unless it's absolutely necessary. Cheers.

[@ACommenterOnYouTube]

Does this motor have a PCV valve on it that may be blocked ??? My breather hose that comes off the top side valve cover that went to the air intake box (removed) shoots oil OUT when im reving the engine in 1st gear ... It idle its fine but as i get into 1st gear and ride off, its spitting out oil ....

[@Jspifferman]

Any recommendations for removing all that silicone if someone else did it? Lol Cant get the plate off its glued down

[@timothymidkiff2894]

Cool video I've got a similar problem with my savage that I need to start working on. Where did you notice most of the oil residue from the leak?

[@kxnrxd4908]

I saw a lot coming out of the valve cover gasket area on top

[@brucebenioff]

next to the exhaust port.

[@brucebenioff]

over and over I hear this oil leak problem. But I don't hear the oi l leak solution.

[@ChaoticCasting]

How did you get to the bolt under the little cover on the seat side of the engine? I have all but that 1 off. I'm stuck!

[@Cosmonnor_]

I was able to fit a small 1/4" ratchet with a 10mm socket there and was able to loosen it, and then unscrew it with my fingers

[@chrisstokley7687]

omg.. : 1 cup oil loss every tank !!! s40... im sure i got small valve cover leaks.. turns allum.. darker color .. like oil seep... some say : sealant was old black type.. and drys out! so i will do as you on red sealant= dat stuff is awesome!.. agrees 1 guy= be liberal the sealant.. like i just smear it thin!!! i use 90 % alcohol to clean it last time before apply sealant 650 heat/ gas risistant RED... ! LET ME KNOW ..what caused leak ? how fixed that plug.. 2 down bro.... godbless

[@samconstant1720]

hey did you ride the bike did it cure the leak I'm about to do the same just debating getting the updated plug or if I should just patch the old one like you did

[@kxnrxd4908]

This completely fixed my (very severe) oil leak. I can’t guarantee this is your problem, but it is a very common one.

[@kxnrxd4908]

And again, I’ve only ridden it another three weeks… so I can’t speak for longevity yet. I’m not sure about the cost of those kits, but I would definitely consider one. Mechanic I mentioned in the video had allegedly applied sealant to this plug mid 2020… and when I picked it apart, there wasn’t any

[@brucebenioff]

@@kxnrxd4908 I sealed the old plug with red permatex the I used a new plug. Neither worked.

[@csj9619]

I suggest getting the new replacement plug because it's made of better material that's less prone to warping/shrinking/distorting from heat cycling.

[@brucebenioff]

The first time I sealed the old plug with red permitex. Than AS PER Suzuki repair manual I replaced the rubber plug over the head bold closest to the exhaust. The Red was applied as permitex instructions a small spaghetti like bead on one side all along the valve cover. Not on the plug. This seemed to work until today I opened the bike up and hauled ass for about 3 miles. Leaking all over the rt fins down the side cover. s--t

[@antondahl8945]

RTV silicone eeeew. Should use Hondabond or equivalent. RTV dissolves into gooey motor worms.

[@stachusrachu4122]

Too much silicon my friend.

[@brucebenioff]

The first time I sealed the old plug with red permitex. Than AS PER Suzuki repair manual I replaced the rubber plug over the head bold closest to the exhaust. The Red was applied as permitex instructions a small spaghetti like bead on one side all along the valve cover. Not on the plug. This seemed to work until today I opened the bike up.leaking

[@chrisstokley7687]

TRUTH: suzuki screw -up.... 2025.. they make a seal that fits super tight ..$ 11.89 + 2.99 tax. + ship .. ;like 15 $ for a rubber plug:>( .. omg. !!!