This is not a new idea but it is a simple little mod that I saw on TLPlanet (//www.tlplanet.com). It is designed to protect the clutch actuation rod seal from all the crap that gets slung off of the chain. This seal is very poorly designed and can be easily damaged, resulting in oil leaking out and later needing to be replaced. Not sure if these seals going bad are a big problem for the GS, but they seem to be for the TLR (odd that the TLS owners do not post as to having this problem)
There are other ways of doing this, but here is the way I did it...
Parts needed: A plastic mechanical pencil (or similar diameter tube) for the sleeve and the flexible accordion part off the top of a mechanical pencil. I used one from a PaperMate pencil. Check to make sure the sleeve/tube will slip over the rod prior to cutting.
Measure the length of the actuation rod that would be exposed. The sleeve is cut to this length minus the length of the flexible part. It is fine if the sleeve is a little longer, maybe 2-3mm. Make sure when the clutch lever is fully pulled in that the sleeve will not hit both the actuator and seal, otherwise damage to the seal could occur.
NOTE: these pics and dimensions are from my TLR. Once I do this to my GS, I will update with current pics and any additional info. The process is the same but the length of the sleeve may be different.
Normal rod:
(http://img.photobucket.com/albums/v64/dgyver/Misc/PenMod01.jpg)
Flexi part and sleeve installed:
(http://img.photobucket.com/albums/v64/dgyver/Misc/PenMod02.jpg)
Flexi part and sleeve lengths:
(http://img.photobucket.com/albums/v64/dgyver/Misc/PenMod03.jpg)
I just replaced this seal (and all the others under that cover).
Just wanted to say that...because it sucked!
NOW you tell me!
After replacing the chain (and cleaning a ton of goo out of there), my GS developed a leak just there - at the clutch push rod... I guess I'll just have to replace the damn seal... It seems a bit late for modding.
Is it hard to do? Any special tools needed?
D.
Yup, mine is leaking from there too. It isn't a bad leak, so I have been putting it off as a winter project.
Chris
That seal is actually pretty easy to replace - the shift shaft seal is a bit more difficult. To replace the clutch rod seal just take the cover off and clean everything up. Then remove the clutch rod. I used a smallish allen wrench and inserted the short side into the opening left by the clutch rod. Lever a bit and the seal pops right out. You can get a new one from bikebandit for a couple bucks. Clean the opening real well, put sealer around the edge of the new seal, then tap it in squarely with a socket.
You'll wonder why you waited so long after you've done it.
Forgot to mention you will have to remove the sprocket which requires a set of snap ring pliers. Not a big deal.