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Discussion Starter #1
Hi,



I have a 2006 TW and have that dreaded base gasket leak. I was wondering how many of you have the new 2010 base gasket and what the success rate is on those? I'm scheduled to bring my bike to the shop in May to get it fixed. I love this little bike and would love to keep it for many thousand more miles. I heard that the cases where the gasket sit might not be perfectly flat so the gasket may not be the end all fix.



Any input would be greatly appreciated.



Ken
 

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I've got a 2006 with the same problem. I'm planning to fix it next weekend. From what I've researched, for the most part, the gasket is the difference. A cheapo was used from 2005-2008 and it leaked whether your cases were perfect or not.



I also found that some people had a case mismatch, in which case it wouldn't matter which gasket you used, you would still have the problem. My plan is to remove the top end, then check the cases. If all is well, I'll put on the new base gasket, a new head gasket, new o-rings, and go back together. Worst case scenario, if the cases are mismatched, I'll make a decision on what to do. Most likely, I will grit my teeth, disassemble the bottom end, match the cases, then go back together.



Make sure to remind the shop to check the case halves, and let you know if they have any doubt about their condition. Splitting the cases will involve several more hours, and a bottom end gasket set, but as the old saying goes, "There's plenty of time to do it right the second time around."
 

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Discussion Starter #3
Rodney,



Sucks that we have to deal with this at all. I'm still a newbie when it comes to motorcycles, but what do you mean about checking the case halves? Are you referring to the right and left crank case surfaces? How many things should they check at a minimum for mating surfaces (head gasket surface, base gasket surface, and crank case surfaces)?



Thanks.



Ken
 

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Basically, there is a left and right case half that encloses the crankshaft and transmission. Underneath the cylinder, there will be a seam in the middle where the two halves meet. If one of the case halves sticks up higher than the other (a mismatch), there will be a step at the seam, and the cylinder won't fit perfectly flush. Then the gasket won't be able to seal and oil will leak out.



The base gasket surface is the main thing they need to check, making sure the halves are the same height, so the seam is flat, and making sure the base of the cylinder doesn't have any burrs. It won't hurt to check the head gasket surface while they've got it apart.



Most likely, all of the surfaces are fine and a new gasket will be all that is needed. At least that's what I'm hoping for.
 

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Discussion Starter #5
Can you let me know what ends up being repaired on yours? I'm bringing mine in May 5th to the local dealership for them to repair. Good luck.



Ken
 

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2006 here. New 2010 base gasket a year or two ago. No problems or leaks since. The stock 2006 base gasket was lousy. New design is THE answer.
 

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I went ahead and replaced mine. Case halves were matched almost perfectly. The new base gasket from the 2010 model was indeed what mine needed. My o-rings were also in really bad shape, so make sure you order those as well. There's one around the cylinder, one for the oil passage between the case and cylinder, and one (tall o-ring like gasket) for the oil passage between the cylinder and head.
 
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