| Author | Message | ||
     Swordsman |
Okay, WHAT am I doing wrong here? I have the primary case off, and I'm trying to remove the oil seal for the shifter shaft, and the thing will NOT come off! I've managed to dig the little spring out, and tear the edges all to hell, but I can't get it to pop out! Looking at the new one, I can't see what in the world would be holding it on so tightly. Any advice? ~SM | ||
| 5liter |
I used a real small straight slot screw driver and just worked it around until it popped out. | ||
| Sparky |
See if you have a small socket that'll just fit in the cover hole and tap the seal out. | ||
| Reepicheep |
Thats what worked well for my Kawasaki rebuild... put a big "catcher socket" on one side, and a smaller "pusher socket" that engages the seal but fits in the hole on the pushing side. Then press if possible, tap if necessary, to get them out. Heat goes a long way to making various seals and bushings pop out if it is tight... probably not a problem for this part, but nice for pushing a crank out of a bearing. | ||
| Spuds |
Can I hijack this thread please? With some 30,000 miles on the bike, I thought that maybe this winter I should pull the primary cover off, see if there's any muck in there that might need cleaning out, mostly due to the recurring water in the primary issue.... All I want to do, is pull the cover off, have a look, clean the area up a bit if necessary, install a new gasket and put the cover back on. So. I carefully read the service manual. The whole process seems straight forward. I then pop onto BadWeb and see if there's any info here that might help, and find this thread, and think...great...gonna have to muck around with what's likely a $0.10 part that's gonna give me grief. I make the mental note that getting this seal out will require some effort. On page 6-4 of the 2003 xb9r service manual, the instructions say, at step 5, "remove shifter assembly and rubber washer." Sure enough, on the shifter "shaft", behind the whole shifter assembly, there's a plasticy/rubbery washer, that simply pulls right off the shaft. Easy. I like easy. Then in the manual, right under this step, there's a NOTE that indicates that the "shifter shaft seal" should be replaced any time the primary cover is removed. Question 1: Is this "shifter shaft seal" the rubbery/plasticy washer that is referred to in the previous step and that simply slipped right off? The diagrams in the service manual aren't totally helpful/clear on this. At first I thought, na, given the existence of this thread to begin with, there's gotta be another seal to deal with. Eventually get the primary cover off, the biggest challenge here seemed to be its willingness to come over and away from the shifter shaft. There certainly appears to be a soft "seal" of some sort in the exterior lip of the shifter shaft hole on the primary cover. This "seal" took a bit of a beating during the cover removal process. I'm HOPING that this "seal" is the "shifter shaft seal" that ultimately gets replaced, cause...I've hacked away at it and there's no way that it's gonna seal anything in the future!! The manual goes on then (at step 13) saying that once the gasket is discarded, that the shifter shaft oil seal should be removed and discarded. So, I think I've concluded that the "shifter shaft oil seal" is in fact the piece that was troublesome, and that I'll simply get a new one and the dealer, and all will be well. (Right?) This all brings me to question 2: assuming that that hacked up seal in fact the "shifter shaft oil seal" that needs to be replaced,....how the heck will the new one go in once the primary cover is (as per the installation instructions) back on the bike, without damaging it to a point of uselessness? Sorry for the length of all this - I wanted to be as precise and clear as possible!! r | ||
| Reepicheep |
You are on the right track. Your only error is to assume that when you put in the new seal, it will seal.  Getting those things in without bending them is an art. I totally buggered it up when I first tried it with the cyclone nearly 10 years ago. I've had a lot of experience with dirt bike cases and seals since then though, so I am cautiously optimistic it'll go better the next time I try it. That being said, the XB9SX has had a slow weep from there for a year or so, and my solution has been to hose it down once a month. | ||
| Spuds |
OK....thanks Reepicheep. I'll make sure I do everything I can to get to a "zen state of mind" before sitting down to put that seal in then.... Rod | ||
| Reepicheep |
Good luck! It'll probably go fine. For me, nothing like having a second new seal sitting around to achieve one-ness with the universe  I bet a local bearing shop could source seal off the shelf for a buck or two if you bring the old (or new) one in... | ||
| Spuds |
So, tho existing shifter shaft oil seal eventually does come out in pieces...even requiring me to dig/pry a little to get the inner-most "layer" out (that ALMOST looked like it could have stayed there....but no--it's gotta come out). The primary case went back on fairly easily - once I realized that the slack in the primary chain itself needed to be 'lifted up' so the adjuster shoe could get in underneath it.... Buttoned it all back up again, and then gently tapped the new shifter shaft oil seal into place using a deep socket around and over the shaft...it's in, feels flush around the outer edge with the case itself, it all 'looks' good! Thanks again all for the advice. Rod |
