Clutch Cover Oil Leak - 2001 EC200
 

Quick FYI - I put my bike back together last week (2001 EC200/250) and had a severe oil leak from the bottom of the clutch cover. I tried to retighten, with no luck, so I pulled the cover and made a new gasket out of some thicker more durable felpor material. When I reassembled, I discovered the real reason for the leak.

The lower bolt (6 o'clock) position was too long, and would not allow the cover to fully seat. The parts list shows the 2 length of bolts, 2 long M6x75 and 3 short M6x25. For what ever reason, one of my long bolts was 80mm. If the 80 was in the upper position (11 o'clock), it seemed to have no issues, but in the lower it bottomed out. The cover was snug, but not tight.

I have a parts bike, so I pulled those bolts out, and the were just like the parts list, both the same size. I replaced the 80 with 75, fitted up very nice, and no leak!

Could save someone headache!

It looks to me like the 80mm bolt belongs in the water pump area #20 in the parts list, you may find a 75mm in that spot on your engine. Good tip though, Thanks

If you remove a cover/case/s from your motor with varying length fasteners, all you have to do is drop all the bolts into the holes and compare to see that they all have the same gap form the bolt head to the case. If if end up with varying gaps just move the bolts around to obtain the same gaps and you will be good to go. All the case/cover bolts will generally have the same amount of used thread.