I think my GS has developed a leak from the shaft that the shift lever attaches too. Is this a common problem. How hard is it to fix? I used to have leaks from the oil pan gasket and alternator side cover gasket. They used to leak when I actually rode the bike. Now it leaks a little no matter what, and I believe from this spot.

Would it be more worthwhile to just let the dealer handle it? Thanks

Patrick

It's not a common problem, but it has happened before: http://gstwins.com/gsboard/index.php?topic=22507.msg225526#msg225526

More links to follow.  I'm searching using 'shift shaft seal'.

http://gstwins.com/gsboard/index.php?topic=23483.0

Also, check to see if that really is the problem: http://gstwins.com/gsboard/index.php?topic=23326.msg236870#msg236870

This is promising:
http://gstwins.com/gsboard/index.php?topic=4699.msg37756#msg37756

Cool thanks for the links so far. By the way. Does anyone have one of the gas tank filler cap gaskets? The one that is on the filler cap on mine is about gone and leads to gas on the crotch at times..

Patrick

Oh yeah, when I got the bike, it had a entirely to tight and too short chain on it. I do see the leak around the shift shaft though.

F3

I thought I had a leak on the shift once but it turned out to be chain-fling, several other board members have had this. Have a good clean up and observe carefully before starting to dismantle anything.

Quote from: Wrecent_Wryder on March 18, 2006, 05:18:46 AM
... but, does that mean that the alternator (rotor, stator, whatever) is bathed in oil in operation? Thats... odd.

Yes, this is what you get with unit crankcase construction.  On certain bikes, they are called oil-warmed alternators, which means that the hot oil eventually melts the insulation.

Quote from: Wrecent_Wryder on March 18, 2006, 05:18:46 AM
Fascinating info in the links... but I'm a little confused (not unusual).
There are lots of references to the leaks in the alternator cover gasket. Ok, I happen to have a spare cover and gasket (long story, uninteresting), and it's a pretty elaborate gasket, which would certainly lend credence to the idea that there's oil behind it...
... but, does that mean that the alternator (rotor, stator, whatever) is bathed in oil in operation? Thats... odd.

The generator isn't so much bathed in oil (like the clutch for instance) but there are passages between the crank gallery and the left side. This is mostly to give incidental mist oiling to the starter gear train, which is in the same compartment. If the bike has laid on its left side, then oil will have flooded the area and if the seal has any imperfections, then it will leak.

I second the notion to clean up the side really well, especally remove the sprocket cover and clean under there and the chain, to make sure that your have the true souce of the leak.

Quote from: Cal Price on March 18, 2006, 06:36:01 AM
I thought I had a leak on the shift once but it turned out to be chain-fling, several other board members have had this. Have a good clean up and observe carefully before starting to dismantle anything.

I had this, I took off the front sprocket cover and inside was filled with thick chain oil, so I cleaned it all out.

S3

Ah, but the crank has a seal, and if that seal goes you will want to know about it.

Its not the chain oil. It is always the same color as the oil. (if new light brown, then with age turns black). it also leaks just sitting. And is starting a healthy pool.

I will post some pictures soon. I am currently installing my new motor in the 998 so no time right now.

So how can you repair/replace this? Is it hard? What will I need?

-Patrick

The hardest part is getting the old gasket out. Easiest way usually is to drill two holes in the metal jaket of the seal, wrench in two parker screws an pull those out. Of course once you have the holes in there you are doomed to pull through.

Oh God, not this again.

All I will say is buy the manual (Suzuki or Clymers) and follow the instructions.

I had that same gasket go on, got old and crusty, had to ship the sucker off the side cover. now the gasket on the other side is leaking, not as bad but it's defintaley going. Problem is I can't find which one it is online. It's called the crankcase cover gasket. But none of the fiche names are complete enough for me to figure out which one it is. <sigh> anyone have a part number or suggestions?

A gasket isn't a special magic thing, it's just some gasket material (glorified cardboard) cut to the propper shape. I hate dealing with dealer hassles and prices so I just bought a roll of gasket material for $3 and am going to cut out my own gasket. My oil pan gasket is leaking so I'm going to trace a borrowed one from chilly willy and use that.

If you don't have someone that you can borrow one to trace, you can just use your old one or the engine piece. If you smear some grease on the gasket surface and press it on the gasket material it will leave a nice outline of where you should cut. I usually get fairly thick stuff (1/32") to take care of any minor warpage and then use a good gasket sealer. I haven't done this on my current bike yet but I worked at a shipyard as a machinist and made plenty of gaskets without problems.

The only ones that you shouldn't make are the cylinder head (high pressure) and base (affects copression height) gaskets. and some other special ones.

have fun 

Now that is a damn fine idea. Thanks  can I pick up the gasket material from pretty much any auto parts store or what? Is the gasket sealer neccesary or can I just pre-soak it in oil like the Clymer says?

I got mine at a hardware store (Ace) but most auto parts stores should have it. Get the high temp stuff. I've always used a gasket sealer (permatex high tack) with good results, it's like rubber cement so that you stick it to one side before assembly and it makes it really easy. Soaking it in oil would probally work too though. Of course the seals for the shifter shaft would be a little more difficult to do yourself, since it's a moving part but you could try felt soaked in oil  probally not worth it though. The non moving parts are much easier to do yourself. 

I'm just gettin a leak from the left crank case cover and I can't find that big funny shaped gasket that goes there so i'm more then happy to give makin it myself a shot. So pretty much any chemical and heat resistant gasket material of that thickness should work huh? Cool 

Any chemical? don't know what you mean, but if you're talking about gasket sealer, no not any chemical but probally any gasket sealer would work. I wouldn't recomend a silicone or RTV because that stuff is usually used insted of a gasket, not with one.

The oil soaking method will probally work, hell probally using nothing will usually work okay, but for the hassle you go through replacing the thing, I think it only makes sense to spend a couple of bucks on gasket sealer. I use it on pre made as well as home made gaskets and one bottle will last forever.
Good luck, I'm going to sleep 

Oh I meant for the gasket material but I checked Ace's site and a couple others and see it's just a generic automotive gasket material made specificily go figure  :icon_mrgreen:Think I'm all set now, thanks again