Shift Lever Oil Seal / Clutch Push Rod Seal..yes I searched

[ctandc]

Searched here, and on several other forums.

Victim: 90 GS500E

Symptom : ONLY after running, bike leaks small amount of oil that ends up going down the sidestand. Almost 700 miles on it, since I bought it, and I haven't had to add oil yet. But it's annoying. Does not leak when sitting without having been run.

So I pull the sprocket cover, hoping it's the infamous chain lube / gunk build up. Nope. Cover was pretty nasty...but nothing crazy. So I cleaned it all out. And from the way it was sitting (centerstand) the oil looks to be slowly leaking from the shift lever.

I'm going to order the oil seal for the shift lever and the clutch push rod, so I can just do both while I have it apart.

Now..I've got the Haynes and a PDF of the Factory Suzuki GS500 manual. It 'appears' to change the shift lever seal, I could just remove the sprocket, remove the bolt on 'cover' / plate that goes over where the shift lever seal is, then get the old seal out. I have several seal removers...and even if they didn't work, I would think drilling a couple of small holes then using self-tapping screws to work it out would suffice. Driving the new seal in wouldn't be an issue...an appropriate piece of hollow pipe and a washer looks like it would work without a problem.  now of course, cleaning out where the new seal goes, and coating the new one with some gasket adhesive (not silicone).

In my searches it seems that several people had a leak, checked the shift lever seal, and their seal was 'popped out' and some simply seated it again and the leak stopped.

Since I'm in there, I figured replacing the clutch push rod seal as well would be the smart thing to do...especially as cheap as the part is. It seems to be just a matter of pulling the clutch rod out and then getting the old seal out, and driving the new one in.

Any first-hand experience with these would be great.

My bike dribbling everywhere is getting annoying.

[nastynate6695]

welcome my friend...Sorry to hear about your problem... leaking or using a lot of oil is one of the problems with the gs  from time to time...I just had to replace my tack cable seal where it goes into the block along with oil cap and right side engine casing seal.  As far as changing the ones you are looking to do i havent touched them...But i would have to agree with you. That while you were in there  you should change a couple other seals also.  Especially with the year of the bike.  If you have the manual it shouldnt be a major problem  you just need the tools to get in there.  AS far as someone around the forum changing it out i dont know of anyone but i can almost bet you dgvyer  has...

[GeeP]

I haven't changed one either, but I think your plan will work just fine. 

Of course, if you do resort to sheet metal screws and drilling, be certain not to go deeper than the thickness of the seal.  (DUH)   

[scratch]

The clutch rod seal is easy; just as you described.  I haven't done the shift shaft seal, so I dunno 

[Gisser]

Don't think the face of the shift shaft seal is wide enough to use the sheet metal screw method.  A curved, pointed awl is probably the way to go.  Either way, just be careful not to gouge the shift shaft because with that skinny seal there isn't much margin for error.