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I seriously doubt your oil leak was caused by the switch to synthetic. Take a close look at that S shaped fat hose from the breather in the frame to the top of the bellhousing . That hose if original is 15 years old and engine heat will cause it to crack, somewhere above the clamp, and it can leak down into the bellhousing from on top, and come out the weep hole on the bottom . Mine did that once where the hose clamp was only loose, allowing oil to work its way down the outside of the pipe.I hope it helps in your case,Rick.
Problem is the Hydros don't have that hose. From that model on the breather was relocated to the timing chest so that eradicated that leak point in the bell housing! Sounds like it probably is the rear seal.The reason the hydros have a 5w40 specified is to get the flow to the lifters quickly so they'll pump up fast. I reckon in reality it won't make a lot of difference, especially in a hot climate. I'm pretty sure my mate Peter uses the same Penrite 10/60 in his Hydro as he does in his Griso and Stelvio and his bike purrs like a kitten. It's worked hard too as it's lugging a heavy outfit in tropical far North Queensland.When I get my turd running again I'll probably start it up on 5/40 and run it for a couple of hours before draining and swapping to 10/60 after which I hope to never have to worry about it ever again!Pete
I put sealant around the fitting that protrudes out of the bell housing to prevent oil from leaking around it and into the bell housing from the end of the hose. Did this when I had the engine out for clutch replacement. Figured it couldn't hurt anything and only help keep other contaminants out.
Both hydro's I have, still have the bell housing return fitting that attaches inside to the crankcase. Nothing in the time chest cover. First I have heard of a return line in the timing chest.
Problem is the Hydros don't have that hose. From that model on the breather was relocated to the timing chest so that eradicated that leak point in the bell housing! Sounds like it probably is the rear seal.Pete
As for the leak, look in side the bell housing peep hole, see oil? Rear main. Don't see oil? My bet is on it leaking around the rear bearing carrier gasket like mine. Probably caused by following the dipstick oil level and not the manual specs...