Clutch Pushrod Oil Seal Replacement - What's the trick?

jdigga

So I replaced the clutch pushrod oil seal last weekend. Started the bike up and to my dismay I saw a large (and growing) puddle of oil on the garage floor. Evil or Very Mad

Lost a perfect riding day because of it, too.

Bought another seal (actually 2 more in case I screwed it up again) the other day and put it in. This time I was a little more gentle but I still succeeded in tearing off a portion of the little outer lip.

(Photo courtesy of Mike's)

I wanted to let it sit for a couple days so I could watch for any more drips and to avoid losing another pint. So far it looks okay so I might run it this afternoon.

Looking at the hole where the seal goes I see a little groove that would seem to be where the lip on the seal should interface. But how the heck can I get it to do that if I destroy it on installation? Also, is the seal supposed to sit flush or do I push it in until it bottoms out?

Wrench time > ride time = Crying or Very sad

kingwj

From MikesXS technical tips:

14. Q. Oil leaks from my engine . Where is it coming from ?
A. Likely from the Clutch pushrod oil seal. This seal was never designed to be replaced without splitting the cases but can be if you are carefull. The seal hole should be chamfered (razor knife will do it) and the new seal must be tapped in place very straight & square to the hole (coat the seal edge with gasket cement first). Repeat if it does not work first time.

jdigga

Bogus... Well, at least I have another one ready. Thanks!

grizld1

Pick up a chamfering tool at the hardware store (lots easier to use than a razor knife) and smooth the edge a bit with 320 paper when you're done (stuff the hole first so you don't leave any grit).

Put the seal in the freezer overnight to stiffen the rubber, and use 3-Bond 1104. The seal should push in with thumb pressure.

jdigga

Cool--do I push it in as far as it'll go or only until the face of it is flush with the hole?

grizld1

Same diff, really; it'll bottom about when the face is flush.

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