Clutch pushrod oil seal

[kettle738]

Hi, has anyone got any experience of replacing the clutch pushrod oil seal without large scale dismantling?

Looking at the parts book there are two seals, I was expecting the clutch pushrod to be a simple straight rod and to pull straight out as per most Japanese bikes but that is not happening as it appears to have a fitting at the clutch end which prevents that.

That makes the job of replacing the seals, outer, inner or both that much harder.

Any tips on this job guys?

Mick.

[FC Zach]

Unfortunately the right side has to be disassembled in order to remove the rod. As far as removing the seal without major disassembly, I'm not too sure on that. Somebody may have some unique ideas. At worst you'll just need to drain all the fluids, use another gasket, and top everything back off.

[kettle738]

Thanks, ideally I would like to remove the outer seal with the push rod in situ and then slide a new seal in over the rod and gently drift it home possibly with a little sealant around the outside.

I was hoping someone might have done this and I'm looking for tips to remove the outer seal with the push rod in place without damaging anything else.

Hopefully someone on this list has done it, I can't be the first to have a weeping pushrod seal.

Mick.

[steveuk]

can you screw in a small self tapping screw into the old seal and gently pull it out with a pair of pliers

steve

[Jess]

Drain the transmission.

Dig it out... Doesn't matter how bad you tear it up. The screw idea will work, use two. One on either side of the push rod. Then you can pull it straight out. I, personally, just use a pick and work around it until it pops out. You can then press a new one in with the push rod in place.

DON'T use sealant. The seal will suffice. While you are at it, replace the one on the inside of the cover.

They are in stock and available at RR.

One caveat... that is not the only place the trans can leak under the cover. The gear indicator switch assembly is often the culprit for leaks "blamed" on the clutch push rod seal.

If the leak is constant, it is most probably the switch. If the leak only happens when the bike is on the sidestand, clutch push rod seal.

Just my 2 cents...

Best,

Jess

[kettle738]

Thanks Jess, advice much appreciated, I will work out what else I need and place an order.

Regards..........Mick.