Oil cooler leak

Discussion in 'GS Boxers' started by Britome, Feb 13, 2013.

  1. Britome

    Britome Get Free

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    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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  2. Dan Cãta

    Dan Cãta Long timer

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    Where is it leaking exactly? At the metal part or at the pipe part?

    Dan.
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  3. Britome

    Britome Get Free

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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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  4. mouthfulloflake

    mouthfulloflake Not afraid

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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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  5. Britome

    Britome Get Free

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    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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  6. scooteraug02

    scooteraug02 Dog Rancher

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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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  7. Britome

    Britome Get Free

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    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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  8. scooteraug02

    scooteraug02 Dog Rancher

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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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  9. def

    def Ginger th wonder dog

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    Radiator shop...quit screwing around and have a pro fix it.
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  10. Britome

    Britome Get Free

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    So I blew air into the unit and here was the obvious breach...

    [​IMG]

    It looks like something is damaged underneath this plate.
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  11. def

    def Ginger th wonder dog

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    OK, now what?
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  12. Britome

    Britome Get Free

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    I try the radiator shop
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  13. scooteraug02

    scooteraug02 Dog Rancher

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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.

    [​IMG]
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  14. Britome

    Britome Get Free

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    True. Sorry. However, I just got it welded and will check it out.
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  15. scooteraug02

    scooteraug02 Dog Rancher

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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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  16. Britome

    Britome Get Free

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    Went to radiator shop and they couldn't weld aluminum. Went to another place and both mounts had stresses ou the rivets. So the ground the. Down, welded and then welded the brackets back on.

    Did a pressure test with water and them rode it at high rpms and all looks good. [​IMG]
    [​IMG]
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  17. Britome

    Britome Get Free

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    I'm still a bit paranoid and may look for a used one as a back up.
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  18. mouthfulloflake

    mouthfulloflake Not afraid

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    I thought you had one on order?

    anyway, it is likely fixed.

    I guess it was an old school radiator shop that could not weld aluminum.

    it also seems like the cooler was a causality of the crash.
    Was yours made by KTM? just curious?
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  19. Britome

    Britome Get Free

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    Not sure who made the cooler. I had to got to a classic welding shop.

    Unfortunately I noticed oil on my bike after the test ride and am not sure if it was left from the quart that sprayed all over my bike or if I still have a pin hole.

    Either way, the new/used cooler had already shipped from England before I could call of the sale.
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  20. Britome

    Britome Get Free

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    Looks like the oil cooler weld is good and all the oil is from the quart that was sprayed and dripping lower. Odd thing is I have one persistent drop (not drip) that accumulates on the oil line where the metal meets the rubber. Not sure if i should be concerned.
    #20