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Discussion Starter · #1 ·
Hi all!

the bike is a Hypermotard 939SP 2016.

Changed the front sprocket one tooth down, and disassembled the Footpegs bracket ( two allen screws 12 head and one 24mm socket at the top).

sprocket installed and entered all the screws. Tried to tighten sprocket with 186nm. While doing this the shaft turned a little. Had to wait for a friend of mine to hold the bike and pull the backbrake.
It stood on the sidestand over night.

Today I disassembled the footpeg again to get the socket (32mm) on the front sprocket for tightening. Then all of a sudden gear oil starts to pour from the threaded hole that goes in the engine block. Figured out I missed a washer from yesterday, and it is possible that I switched the 20mm long screw with the 30mm one. But I’m serious, when I assembled it all every screw went in smooth as butter and felt natural. I cannot imagine that i «bored» through the engine block or a seal of some type as i felt no resisting.


Is it possible that I have ruined something here? If so, I have some solutions.
For me its crazy that its even possible to do this. Call me stupid or whatever. I just need an answer..

when inserting the screw with washer it stops pouring. Haven’t tried driving it yet.
Also worth mentioning, I have a mechanical background, and this is not my first bike. Shall I plug the threaded hole or is it supposed to be like this? The hole oil is pouring from is where the item 24 (le

looking forward to all your answers. And sorry for my bad english...
regards
Frans
975673


975672
 

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Bolt #22 is longer than #23. I have mine apart right now. Are you sure you didnt crack the block when you tightened down #23 and the 3rd bolt that holds the kickstand? Those 2 bolts go right into the case where the oil rests. They arent open all the way through into the engine, they have a bottom to them. #22 is a casting outside of the oil cavity so it wouldn't be coming g from there. One other thing to note, on the sprocket, there is a spacer behind it. That spacer has a seal around it as well as an o ring inside. Make sure those are intact and in good condition. Might be leaking from there too.
 

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Discussion Starter · #3 ·
Hi and thanks for reply. The sealing and spacer for front sprocket is all good. Do you know how thick the bottom is at the threaded hole? Seems impossible that I cracked the block... what the hell do I do then? Plug the hole?..
 

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Both holes that are into the oil pan are 28mm deep. If you were to have cracked it I'm not sure what to do. I have read of cracking right there due to excess stress put on the kickstand. (In my pic, notice that one of my kickstand/rearset bolts is different, it fell out a long time ago. I went to a bolt supplier and this was the best option for replacing it at the time)Other possibilities are, under the sprocket itsself is an Allen head bolt. It's not just a bolt, it's an oil passage for the wet clutch(if i remember correctly). There were dry clutch conversion kits for this engine architecture (848 and others) that required that to be removed and a block off needle installed(there were kits that didnt require this as well). Maby that allen head is loose. It would most definitely cause you to see oil on the ground if it were loose/out. One more possibility, this engine architecture is shared among many bikes. They have the provisions to run the normal hydraulic clutch system as opposed to the cable actuated(I did the conversion a while back. Very happy with the mod). Normally the bike comes with a block off plastic piece with o rings on it. It was incorporated with the plastic cover that covers the sprocket. If you didnt put that back in you would definitely have oil on the ground. In this pic you can see the Allen head I was referring too as well as the hydraulic actuated clutch pushrod in the hole. That hole usually has a plastic plug in it if you are using the cable actuation.
975746
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This is the plastic plug that you should have if you are using the cable pull clutch. It gos under the sprocket cover where you see the pushrod sticking out on mine
975747
 

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Discussion Starter · #6 ·
I can clearly see oil pouring like a river if I undo the screw. The screw in the middle of your first picture is where the leak is.
Im afraid I have cracked the case somehow.. wtf... I have to inspect the hole and see how bad it is.. but it was smooth as butter all the way in. No power at all, and all of a sudden I’m through the block? Does not make sense...
 

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Shouldn't have broken that easy. If it's not cracked you could just use some thread sealant on the bolt. Post a pic when you pull it apart. I'm curious to see the crack if there is one.
 

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Discussion Starter · #8 ·
Shouldn't have broken that easy. If it's not cracked you could just use some thread sealant on the bolt. Post a pic when you pull it apart. I'm curious to see the crack if there is one.
What do I do if there is a small crack? Thinking of plugging the hole with a set screw and some red Loctite 262... what do you think?
 

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I have no idea at that point. Share some pics so I can help brainstorm ideas. Depending on how it is cracked, you will need to stop the crack from spreading. The is usually done by drilling a hole at the end of the crack then filling it back in with weld or brazing rod. Share some pics.
 
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