Replacing clutch shaft sealing ring??

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by viola-tor, Jan 13, 2012.

  1. viola-tor

    viola-tor Needs to ride!

    Joined:
    Feb 27, 2008
    Oddometer:
    2,071
    Location:
    Rockies. Freakin' Rockies.
    I'm leaking from this spot, after a maverick rock took out my clutch slave. I'm all up and running again, and I could live with this small leak, but if I can fix it from OUTSIDE the engine case (and on the bike) I figure I might as well.

    It's the #3 in this pic from the manual, part # 600.29.043.010
    Any tips for getting that off and on again while the bike is assembled? Can it be done from the outside?

    [​IMG]
    #1
  2. Zuber

    Zuber Zoob

    Joined:
    Sep 28, 2004
    Oddometer:
    2,631
    Location:
    Main Street, Shedd, Oregon
    Easy fix. You can only replace this from outside the engine. Do a search on 'clutch pushrod seal'. You pull the quick access cover over the clutch, pull the springs and the cover, pull out the shaft, then replace the seal.

    It is difficult to align this seal and get it into the bore. There is a special tool, but it doesn't help. I'd suggest getting several seals, they are cheap.
    #2
  3. gefr

    gefr Life is a trip

    Joined:
    Nov 26, 2005
    Oddometer:
    4,632
    Location:
    East Med, Greece
    You have to remove the slave cylinder on the other side of the bike and remove a pin that holds the pushrod in place.
    Zuber, did not understand the "aligning of the seal and get it into the bore" part. Could you explain please?
    Cheers.
    #3
  4. StevenD

    StevenD Hmmmm, dirt!

    Joined:
    Aug 3, 2005
    Oddometer:
    1,272
    Location:
    Holland, Amserdammed
    No real need even to take out the shaft. get a pvc pipe that fits over the shiftshaft to push the seal in place.
    #4
  5. zedtours

    zedtours Been here awhile

    Joined:
    Jan 17, 2006
    Oddometer:
    500
    Location:
    Surrey
    You all seem to be talking about different seals!
    #5
  6. Zuber

    Zuber Zoob

    Joined:
    Sep 28, 2004
    Oddometer:
    2,631
    Location:
    Main Street, Shedd, Oregon
    The bore that holds this seal has a lip on the left side. If you push the seal straight in it will catch on this lip and ruin the seal. It exists on the 950 engine, might not exist on the 990's. You can't see it in the picture.

    You have to angle the seal in on the left side until it clears this lip, then straighten it and push home. Get a few seals to practice on.
    #6
  7. viola-tor

    viola-tor Needs to ride!

    Joined:
    Feb 27, 2008
    Oddometer:
    2,071
    Location:
    Rockies. Freakin' Rockies.

    Ahh, okay, I'll check it out. Thanks for the heads up! This is why I love this place. :deal :clap

    Tips on removing the old one? I have an assortment of metal hook tools and such...
    #7
  8. Geek

    Geek oot & aboot

    Joined:
    Jun 8, 2003
    Oddometer:
    33,294
    Location:
    8000ft.
    :freaky

    [​IMG]
    #8
  9. viola-tor

    viola-tor Needs to ride!

    Joined:
    Feb 27, 2008
    Oddometer:
    2,071
    Location:
    Rockies. Freakin' Rockies.

    Excellent. Can do! :1drink
    #9
  10. StevenD

    StevenD Hmmmm, dirt!

    Joined:
    Aug 3, 2005
    Oddometer:
    1,272
    Location:
    Holland, Amserdammed
    Fat wood screw works for me, just dont go too deep!
    #10
  11. viola-tor

    viola-tor Needs to ride!

    Joined:
    Feb 27, 2008
    Oddometer:
    2,071
    Location:
    Rockies. Freakin' Rockies.
    Well, I got it out and replaced, but I marred the mating surface on the case with the hooks. :bluduh That metal outer ring on the seal is a biatch!

    I slathered the new one with black sealant and installed, but I've still got the leak (or perhaps a new leak, actually). How do I fix this? JB Weld and file it down? I have two more seals on hand... Surely there is a clever way around this. :ear
    #11
  12. viola-tor

    viola-tor Needs to ride!

    Joined:
    Feb 27, 2008
    Oddometer:
    2,071
    Location:
    Rockies. Freakin' Rockies.
    Anyone? What's the mechanic's fix? :ear:ear:ear This has to happen around the shop from time to time.
    #12
  13. 666

    666 Agnostic and Orange

    Joined:
    Feb 23, 2005
    Oddometer:
    1,327
    Location:
    San Francisco, CA
    May be some locktite gasket maker around the seal?

    I usually drill 2 small holes into the the metal part of the seal, then screw couple of woodscrews in and pull the seal off. I didn't do it on 950, but did on 640 and 450
    #13
  14. viola-tor

    viola-tor Needs to ride!

    Joined:
    Feb 27, 2008
    Oddometer:
    2,071
    Location:
    Rockies. Freakin' Rockies.

    That's a good tip for next time! Hadn't thought of that, sounds like a great way to remove a seal. I'm not sure how well it would work for this one, the center rubber bits seemed to rip out easily while the outer metal ring was more stubborn... But I'll def try if I end up doing this again soon (likely).

    My new problem is that I've damaged the mating surface with my hook tools, so I'm leaking around the outside of seal. FIX??? :ear:ear:ear
    #14
  15. 666

    666 Agnostic and Orange

    Joined:
    Feb 23, 2005
    Oddometer:
    1,327
    Location:
    San Francisco, CA
    try locktite , may be 518 gasket eliminator? Apply it to the case before gasket installation? Check locktite website for correct application. Also I just used loctite to repair wheel hub on 450, ID got so big that wheel bearing was loose. It worked.

    Your earlier jb weld suggestions is not a bad idea, just clean up hole after it sets with the right size reamer(by hand).
    #15
  16. K2m

    K2m ....58....

    Joined:
    Feb 27, 2005
    Oddometer:
    2,238
    Location:
    Sydney Australia
    Might be overlooking something here. You say a rock took out the slave? It may have put a very slight bend in the clutch rod, which would explain the seal which in leaking now but not before. Good luck with it mate, and thanks again Zuber for your excellent input.
    #16
  17. viola-tor

    viola-tor Needs to ride!

    Joined:
    Feb 27, 2008
    Oddometer:
    2,071
    Location:
    Rockies. Freakin' Rockies.

    Hmmm, ya, could be. It was leaking before (why I wanted to replace the seal in the first place), and I'm sure I've now gouged the mating surface (doh!), so it's possible it is leaking from both places... I had the clutch rod out and no warning flags went up, but I wasn't specifically looking to see if it was bent. It slid in and out just fine. I'm not thrilled about taking the clutch apart again, but now I have it down to 15 min or so. :D

    I think I'll give the seal replacement one more try and try to clean up the hole better, both the oil AND the gouging. Then use blue gasket maker around the seal perhaps?? It's pretty tacky.

    Thanks for the ideas, keep 'em coming! Apparently I'm still not above doing dumb stuff in the garage... Part of the bonding process with these orange beasties I reckon...
    #17
  18. Masa

    Masa Been here awhile

    Joined:
    Sep 25, 2011
    Oddometer:
    303
    Location:
    F1nland
    Take the slave unit and all the spacers out, clean the seal area well, start the engine to see where it's leaking - around the shaft or outside of seal. Also check seal alignment from all angles with good light, maybe it isn't seated straight.

    If you replace seal, with sealant perhaps, check for leaks with engine running before assembling slave.
    #18
  19. sonoran

    sonoran copacetic

    Joined:
    Sep 28, 2009
    Oddometer:
    31,041
    Location:
    Undisclosed
    Alright, my turn at bat for this seal replacement. :bluduh

    Don't want to suffer the same fate as Viola-tor. Is there a better way to remove the old seal then pry it out with a hook? :ear
    #19