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Discussion Starter #1
I have the dreaded leak. Part of the seal fell on the ground last time I was working on it. I'm debating gluing a new seal to the outside... and going all out on a full rebuild.


The bike has about 84,000 miles and it's in amazing shape other than that leak, but I can't help but think that maybe a full rebuild might shock me with some HP I didn't realize it's lost with age...


I've googled and haven't seen any full kits for a K5 750 rebuild, seems like they are just losing love with their age. Can someone give me a ballpark on what a rebuild would cost? Are we talking $2k.... $5k.... or?


And if you live in SoCal and have suggestions on a place for the rebuild, I'm all ears.
 

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I've seen a few threads with different fixes, some glued a seal on as you mentioned, some others managed to fasten an o-ring on somehow.

I would try one of these methods before going the rebuilding / splitting the case option.

There is very little pressure on the seal so it would not take much to seal it.
 

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"Part of the seal fell on the ground"

Huh? That doesn't sound good and may rule out what follows.

On my K6 1000 the pushrod OD is 6 mm. Check the part fiche's description for yours and the seal dimensions may be listed. I've heard of people buying a 1/4" precision ground rod and substituting it after cutting it to the same length. It's slightly larger than the OEM and may seal things up. Try McMaster. Among other things, they have several tool steel rods. 4" lengths are common and cheap but that might be a tad short for your purposes.
 

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I ended up doing mine on my 03 K3. Mine was barely leaking but stupid me decided to try it anyway .
I got a die grinder and cut out the lip which is the case. The glue thing I tried , but didn’t work. Actually leaked worse for me. After grinding it perfectly round I was able to install seal. Very difficult still to put seal in. I jb welded it and have over 2k on it with 0 leak. My bike like yours has lots of miles. 150k. I personally wasn’t going to rip cases apart due to miles. You gotta think that the whole Assy is pretty much worn out. If your bike is clean , why not see if a used low mileage engine might be for sale?
 

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Discussion Starter #5
Honestly, I was thinking rebuild/upgrade internals at the same time. It wouldn’t just be about fixing the leak and replacing seals, but about increasing the horsepower and giving the motor a longer lease on life.

I can’t see myself spending $10k+ on a newer bike... but less than $5k to make my bike ride like a new one, sure.

I guess short term I’ll prep the outside for an external seal and finish up a couple other upgrades I’ve put off.
 
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