Shift lever/rubber seal leak 08

[discgolfer2711]

At 1200 miles I began noticing a small but pesky leak coming from the front sprocket cover. The leak works it way down the kick stand and to the pavement. After some research here, I took the sprocket cover off and identified the leak coming from the 1/2" rubber seal that encompasses the shifter rod. I used a 3" ratchet extension to push the seal back in place. It took some effort, but the leak quit for about 1500 miles. I began getting the leak every couple hundred miles after that.  "Spirited riding" seems to cause it the fastest.

Now it's every couple days that it comes back.

At 4700 miles, simply taking the sprocket cover off and resetting it is no longer working.

Has anyone experienced & permanently resolved this situation?

I have two ideas:

1.  Using my dremmel and grinding wheel bit to notch a groove in the top and bottom of the shift rod and getting some kind of retaining clip to snap in

2.  Using some kind of spring and a washer at each end to keep pressure on the seal from working itself out.


I like the spring idea because its not permanent, but springs very a lot, especially with the spring "rate" or rigidity. Might be difficult choosing the best one.


Thanks all,

I appreciate the input.

[ineedanap]

Before you do permanent mods you might want to check your breather hose from the cam cover to the airbox (if you haven't already).  If it's kinked or blocked your engine will build up internal pressure and push oil past your gaskets.  It would be worse with "spirited riding"  Maybe it's pushing your gasket out too. 

It's probably not your problem but might be worth a check.

[sledge]

Assuming its out of warranty............just replace the seal with a new one. Drain the oil and ensure the area is scrupulously clean before carefully drifting it home without distorting it. If it carries on popping out there is an underlying cause.