Looking for any cooling/electrical system upgrades

Reading online (on non-VFR forms), some people suggest putting a tiny bit of JBweld on the gouge, scraping the excess with a razor, letting it dry then sanding it down. If JBweld and a coke can can fix a hole in my dad's BMW 750il engine block 20 years ago (true story), surely it can fix a small scratch on a gasket mating surface?
Another thing I've seen is to use RTV (or ig HondaBond would work too) in lieu of gasket sealant.
Of the two options, I think the first would probably work better. I'm curious for y'all's inputs on this, maybe there's a better method?
I'm sorry I keep going on and on about this. I feel so annoying having to keep posting about my temperamental bike all the time. I'm studying AI right now, hopefully one day I can make a reliable Honda Mechanic GPT so you all can be left alone with my shenanigans... at least right now I'll have some good training data.

 

Yeah... I can't find any Honda gaskets (Part# 11636-MBG-000) in stock anywhere that aren't aftermarket, so I had to go with a Caltric. I've never had much luck with Caltric but if Honda's not making that gasket, it's better than nothing.

 

Mello,

Not available there. Just checked right now.

 

Ah, found one here (via webbike):

https://www.montgomeryvillecc.com/-...031d2a/a55817ce-f606-49ae-bae3-15feda93b909/y

 

As much as I want my bike to work, I'm not driving 1,500 miles for one gasket

 

I found a gasket on eBay from NIPPON MACHINES that looks like it's made from a different material (cork? they say it's made of "gasket material"). Wonder if it's worth a try.
The more I have to pull the cover apart, the more I want to CAD my own gasket. If and when I get a gasket CADed up, I'll be sure to share it with yall to avoid these headaches. (That is, if you happen to own [or work somewhere that has one] a laser cutter)

 

I'm sorry that the gasket is in-store only.

Found the link DIRECTLY from webbike and not a subsidary:

https://japan.webike.net/products/24439143.html?ref=hd_sgg

BTW, an old trick to find leaks is to power-spray the affected area and afterwards disburse talcum powder over the area in question.

The oil leaks should be readily apparent.

 

The 6th and 5th gen gaskets are different. (I'm sure you knew, but I'd like to reiterate for any future readers) I had to do this check because I accidentally bought a 6th gen gasket at first, so I had to contact the website I ordered from to switch it (which they did, thanks BikersRun )
This is a 5th gen gasket:

This is a 6th gen gasket:
Very similar looking upon first glance, but on further looking you'll find that the bolts won't line up.
The stator itself is also different, as discussed earlier this thread, a 6th gen stator is too big to fit in the flywheel. (If needed, you may get some luck fitting a 5th gen stator to a 6th gen, but I wouldn't recommend it)
Why Honda bothered to change out this part between generations is beyond me.

 

I CADed up the 5th gen stator gasket. I haven't got the chance to actually cut it yet, so I don't quite know if it's right, but if anyone wants to take a crack at it before I get the chance to do it, I'll attach the file. If this is successful, I might also mock up my clutch cover gasket (I have a spare one lying around, but I was able to make this CAD design using a JPG of the gasket I found online. The physical one is good to have to figure out how to scale it, though), since that's another gasket I had to buy several of, and I think any nerdy 5th gen owners would greatly appreciate it.
Once both are done, I'll most likely make a separate thread for downloading the finished products.
5th gen stator cover gasket (DXF format): https://drive.google.com/file/d/1bimooWKK1VQKzD6EAOza-GKxrJA4dNy1/view?usp=sharing
This CAD is untested, please do a test print before deploying it.
If anyone does cut this before I do, please let me know how it goes

 

Okay, interesting development.
I pulled off the fairing and I noticed oil pooling around what appears to be two cracks on opposite sides of the stator cover.
I threw some HondaBond on it, let it sit for 19 hours, then let it warm up and rev in my garage for about 7 minutes. The oil leak is now down to a minimum, I'm not sure where it's still leaking from (would like to try pi-on's checking method when I have the materials), but it's now leaking even less. More to come later

 

Hmm - You may want to add David Silver Spares USA to your bookmarks list - they hold a lot of parts for older Honda bikes and sure enough they show having two of those gaskets in stock @ $16

https://www.davidsilverspares.com/parts/by-part-number/partnumber_1209/

 

Rick's Motorsport Electrics sells gen 5 stator cover gaskets. Product # 25-109. They're $13

 

if the stator cover is cracked - possibly after a tip over then rather than try and repair it you might be better off just finding an undamaged replacement cover from a motor salvage yard such as this one for $60

https://www.ebay.com/itm/3257552788...M/tOwscwkxM1EixTpp8m/vyj4A==|tkp:BFBM7JXS2sxi

 

After several attempts and several sheets of gasket material later...

**IT WORKED!**
The bike is no longer leaking oil! I had to change the gasket out several times, and it took several iterations of laser cut gaskets, but I got it all sorted. I ended up making the edges of the gasket a bit thicker than the normal gasket. My first gasket iteration was made with fiber gasket material bought from AutoZone, and it ended up snapping during torquing. We ended up with a rubber sheet, but it's incredibly hard to pierce the rubber with a laser. Either you have to do multiple cuts and clean the in-between the lines between each run, or do what I did and cut once, then cut the outline using a rasor knife.
I'll make a separate thread with the appropriate file for laser cutting if anyone's interested.
I also entirely nixed the gasket sealant and rubbed some lithium grease onto both sides of the rubber gasket.
Whew... only took 9 gaskets to make it stop leaking! It's nice to not have to wait a few days for shipping every time I need to change gaskets. If I end up doing another clutch change, I'll map up a gasket and post it.
Picture is the fiber gasket, I wish I had a pic of the rubber one but I was too excited to put the gasket on.
No more oil leak, plus NTX is finally cooling off... It's time for the real NTX riding season!
Ride safe