FD Outer Seal Pictorial!

Discussion in 'GS Boxers' started by JimVonBaden, Apr 19, 2013.

  1. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    Replaced the FD seal on my friend's bike:


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    Starting, you can see the dust built up on his weeping seal. Not bad yet, but while I am working on it.

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    Use a small screwdriver to lift the seal cover. You may have to add a larger one next to it if you small one flexes too much. Just pry against the dust cover. They are tough, but easy to get off.


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    Using a small screwdriver, pry near the end of the snap ring. Pry on the outer edge of the ring towards the center.

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    Once you get it started it pops out easily.


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    Use a center punch, I like snap punches, to start dimple your seal flange for drilling. I find it makes it easier to find the punch mark through the rubber if you start in one of the convenient dimples on the flat.


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    Drill using a small drill, just smaller than the sheet metal screw you plan to put into it. Once the drill pops through immediately stop pushing. You do not want to damage the bearing.


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    I drilled top and bottom, as sometimes you need to pull on both. In this case I screwed in a sheet metal screw, gave it a tug, and the seal came right out, so I didn't need to use the second screw.


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    Push the new seal in as far as you can, then use the old seal to tap the new seal in to seat. The old seal will not get stuck. Make ture you seat the new one evenly until it stops. Verify it is in good by looking at the clip groove and verifying it is even all the way around, and leaves room for the clip.


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    Snap the new ring in. Make sure it is seated all the way.


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    Place the dust cover in place and tap it in with the palm of your hand.




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    I had previously replaced the balancer seal and the clutch, then did a full 36K service on it, then washed it and set it aside for him to come pick up.



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    Finally, I cleaned the garage in prep for the tech day next weekend.
    #1
  2. Mr. Magoo

    Mr. Magoo Bottom feeder

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    Thank you! :clap You're a real asset to this site!
    #2
  3. TexBiker

    TexBiker Been here awhile

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    Great tutorial.

    Also, the cleanliness and organization of your garage makes me want to burn mine down. ;)
    #3
    mitchapalooza, filmfan and NOTAGAIN like this.
  4. DDT Rider

    DDT Rider Been here awhile

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    I want to come to the tech day!!!!!!!!!!!!!!!!

    Thanks for posting!
    #4
  5. kimokk

    kimokk Been here awhile

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    Thanks Jim! How many miles did your friend have on the bike and what year is it?
    #5
  6. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    Hi Kimo,

    He has 45K miles, much of it hard miles, with a trip and crash in Alaska.



    PS My garage usually is a mess! :shog
    #6
  7. 2712

    2712 Been here awhile

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    jim,

    how about the oil when you remove the seal?

    will it spill all out and do you need to add new oil or will you just lose a few drops?
    #7
  8. SenorFeliz

    SenorFeliz hangin' out

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    +1. thanks again Jim.

    #8
  9. SenorFeliz

    SenorFeliz hangin' out

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    question please Jim. what stops the seal from going in to far? is there a ridge or something? or do you just go far enough to get past the groove for the ring?
    #9
  10. R.J.

    R.J. split personality

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    I just put down some padding down and laid bike on its side. Never spilled a drop.
    #10
  11. SR1

    SR1 Going to America!!!!

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    Nice pictorial, Jim! Looking forward to your answers on the above questions. Thanks!!!!!!!!!!!!!
    #11
  12. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    I did it with oil in and lost about a teaspoon, not enough to worry about.
    #12
  13. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    There is the bearing race that stops the seal from going any further.
    #13
  14. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    It probably wouldn't leak just on the sidestand. It didn't on a different bike I did, but that was an 05. Shouldn't matter.
    #14
  15. Callisto224

    Callisto224 Long timer Supporter

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    Thank you for posting this. You are certainly a fantastic asset to this site! :clap
    #15
  16. DDT Rider

    DDT Rider Been here awhile

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    Yeah, let's hope Jim doesn't become absorbed in some other new hobby like fishing...
    #16
  17. cjack

    cjack Been here awhile

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    Great pictorial. Did you notice any wear on the seal surface? I heard once that frustrated a seal replacement and the reduction of pressure inside the drive was an attempt to minimize that.
    #17
  18. SenorFeliz

    SenorFeliz hangin' out

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    thank you Jim:wave


    #18
  19. genka

    genka SUV hater

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    Thanks! One day it will be helpful for many of us. Bookmarked!
    #19
  20. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    Good question. The seal sealing surface is Titanium, so I am told, but it did show a slight mark. I couldn't feel any groove.
    #20