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Old 07-23-2020, 07:18 AM   #1
1arunem
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Default 2004 DS oil leak

Ok, so I got my buddies DS running again (wiring issues). He had also asked me to see if I could tell where the oil leak was coming from.

Well, looks like I found it but not sure exactly what may be leaking?

If you look at the pictures, it appears to be coming from around the base of the head, where the case/case cover meet. If I look between the metal shroud and the head fins, I can see oil coming out but oddly can also see rotation as if maybe there is a piece of the case cover or case missing/broken and I am seeing the internals rotate. It is very small. Make sense?

Case cover gasket maybe? Coming from below head?

Note the screwdriver tip in the picture is approximately where the leak appears to be. This is just to the right/above the pulse line and oil fill tube. It is running down from just above where the screwdriver tip is and below head fin.

Thanks for any input!

P.S. the area is very clean as I sprayed it with brake cleaner to find the leak. It was very oily and grimy beforehand.
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Old 07-23-2020, 07:44 AM   #2
1arunem
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Default Re: 2004 DS oil leak

Looks like a quick search for Club Car DS oil leak yielded several results leading me to believe it is a case gasket leak...

Thoughts? Thanks!
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Old 07-23-2020, 08:04 AM   #3
big mule
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Default Re: 2004 DS oil leak

I've replaced 2 or 3 case cover gaskets to correct this problem(on Club Cars & Ezgos) both),over time they will "suck" the gasket in on the top of the crankcase & cause a massive leak.We had an outstanding engine rebuild guy here that would take a center punch & "dimple" both sides of the gasket face in these areas so the gaskt would have something to hold on to,he passed away a few years ago but he really knew the ins & outs of all these small engines .
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Old 07-23-2020, 11:22 AM   #4
CP241
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Default Re: 2004 DS oil leak

It's hard to say, you should be able to pull off the tins around the head, and clean it up good for a better view. By the looks of it, you'll want to do that anyway as they tend to clog with grime, grass, dirt, etc and overheat the engine. It could possibly be coming from head gasket where the push rods go through also, and the fan blowing the oil out that direction.
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Old 07-23-2020, 11:33 AM   #5
Fairtax4me
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Default Re: 2004 DS oil leak

If you can see into it and see things moving it's almost definitely the front cover gasket.
The area next to the cylinder has to deal with the most heat coming from the cylinder, so that part of the gasket always fails first. Use an OEM Club Car gasket or you'll be doing it all over again in a year. No sealant on that gasket. Be sure to get a new front crankshaft seal as well.
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Old 07-23-2020, 03:36 PM   #6
buggyAl
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Default Re: 2004 DS oil leak

I have had several with the same issue. What I have learned is that I clean it off very well then slap a glob of silicone on it. Run for a few days it confirm. If the leak stops replace the gasket.
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