Hi everyone. I am facing a back to back issue with my 2023 V4R. I am writing a detailed report here on the problems that I faced, hoping someone would be able to help me out, and so that it helps others. I bought the v4r on July 2023 and at 500 odd km before the first service, the engine check light popped up. Upon taking the bike to dealership, they said that its an engine failure and will need a full replacement under warranty. I was fine with it. They replaced the engine within 1 week and I got the bike back. I rode around 1000km on the new engine, while following the engine break-in (below 8k rpm) as mentioned in the manual. No issues so far. During the first service for this new engine again, I purchased the underseat akra exhaust and they flashed the Racing Evo. I purchased the Racing Pro DTC flash seperately. Post this, I rode the bike for 50 odd km around 10k rpm on all gears and didn't find any issue. I took the bike to track, and while ripping the bike to it's shift indicator, the bike started leaking oil of around 15-20ml from the breather pipe behind the front tyre. I saw that the oil level had gone down. I asked the dealership and they said its fine, as its a racing bike. After topping it up, I rode the bike again on track, for around 40-50km, and there were oil sprayed on the frame of the bike (below the tank), and around 100-200ml of oil leaking from the breather pipe again. The oil level had gone down considerably. I sent it to dealership again, as the oil on the frame was concerning. They asked me for DDA. I didn't record any, but I told them that the bike only leaked oil when I was in higher RPMs. I touched 331kmph on track, as well as had a lean angle of 57 degrees. They said it could be a blowback issue, but also said that when they installed the engine back, there could be a possibility that air filter gasket, water pump and oil seal for the clutch might not have been fully sealed. So they opened the fairings and saw that the oil was leaking from the airbox too. They said that there is a possibility that the cyclone seperator might have pushed the blowback oil/fumes into the airbox due to high rpm pressure. Also the sprint filter was soaked in oil. They decided to change all the gaskets, reinstall clutch cover, refill the oil, change all oil seals, replaced the cyclone seperator and sent it back again. They also kept the oil level in the engine to min just to make sure they dont overfill. I took the bike to track again but rode it a bit on the easier side this time. Maxed to 300kmph, and lean angle of just 45, changing all gears above 11000 rpm, but no redlining. Oil leak again from the same places. The Airbox sprayed the oil on the frame, air filter got soaked with oil, and the breather pipe was throwing oil of around 100ml again. The oil level went below minimum. Luckily I also enabled DDA this time, as dealership asked for it. I sent the bike again last week to them.
They reverted back saying there is no oil leak from any seals. They said the only possibility is that the blowback is originating from the cyclone seperator due to high-rpm usage on the first 2 gears (which they saw in the DDA as I was changing gears at 14-15k rpm), into the airbox which is normal. They asked me to test the bike again this week, while keeping the first 2 gears below 12k rpm, and the remaining gears can be used normally to see if the leak happens again. I will test the bike again this weekend now.
To be honest, I do not understand their logic at this point. But this is the response from Italy. I love the bike and its character, so I do not want any stupid responses asking me to sell the bike. I want to understand technically what could be the possible issues for this, any ways to fix this. Because if Italy themselves is saying its normal, then I might've done a big mistake buying this. FYI, I have a Streetfighter v4s 2022 with full akra, and I do not have any issue on that while being ridden in a similar way. Just frustrated at this point, and any technical support here will be very helpful. Has anyone else faced this issue?