Thanks to all the great info found in this forum I was able to pull the transmission, clutch assembly and the 2 leaking seals on my 2004 R1150RT. I carefully drilled the holes in the seals, inserted self-tapping screws and popped the seals out. Leave it to me to find a new problem - when drilling the last hole on the 2nd seal the drill bit broke and I have a nasty gouge along the race where the seal seats in the engine casing. I have smoothed it up with emory cloth and I was extra careful about not getting sanding debris into the engine. I can still feel a nick after smoothing it up and I'm afraid that the nick will leak after the new seals are installed. Can I fill the nick with JB Weld and smooth it up some more or is it just gonna leak no matter what I do?
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oil seal damage
- Thread starter cwilson
- Start date
Update
I managed to repair the damaged race with JB weld and installed my seals. No leaks after 200 miles of riding, new clutch works great and it shifts a lot smoother now. Getting the new seals in was pretty easy using the 'coke can' trick. Seating the inner seal was fairly easy using my homemade tool (used a PVC pipe fitting). The outer seal was just flush with the crankcase so that was fairly easy too.
Great to be on the road again.
I managed to repair the damaged race with JB weld and installed my seals. No leaks after 200 miles of riding, new clutch works great and it shifts a lot smoother now. Getting the new seals in was pretty easy using the 'coke can' trick. Seating the inner seal was fairly easy using my homemade tool (used a PVC pipe fitting). The outer seal was just flush with the crankcase so that was fairly easy too.
Great to be on the road again.
seals
The coke can trick I read about somewhere (thought it was this forum). The diameter of an ordinary coke can is a perfect fit for the end of the crankshaft.
Lube and pre-form the seal then slide it onto the can. Place the can over the crankshaft end and press the seal into place - try to keep it as square as you can when it touches the crankcase race then use your 'seating tool' (I used a homemade tool out of a PVC pipe fitting - used my router to cut a shoulder into the edge at just the right depth). Didn't think to get pictures of the operation. I'll try to post pics of the tools I had to make.
The coke can trick I read about somewhere (thought it was this forum). The diameter of an ordinary coke can is a perfect fit for the end of the crankshaft.
Lube and pre-form the seal then slide it onto the can. Place the can over the crankshaft end and press the seal into place - try to keep it as square as you can when it touches the crankcase race then use your 'seating tool' (I used a homemade tool out of a PVC pipe fitting - used my router to cut a shoulder into the edge at just the right depth). Didn't think to get pictures of the operation. I'll try to post pics of the tools I had to make.
seal leak
I found the leak when I saw oil on the back side of my bike and traced it to these seals. I removed my starter and could see into the clutch housing. The leak explained 2 symptoms I was having: 1. sudden increase in oil consumption and 2. funky shifting (due to oil contamination on the clutch).
I found the leak when I saw oil on the back side of my bike and traced it to these seals. I removed my starter and could see into the clutch housing. The leak explained 2 symptoms I was having: 1. sudden increase in oil consumption and 2. funky shifting (due to oil contamination on the clutch).
