Oil leak from gear position sensor?

Discussion in 'Dakar champion (950/990)' started by derm75, Mar 16, 2011.

  1. derm75

    derm75 I'm a brother shamus...

    Joined:
    Sep 14, 2007
    Oddometer:
    462
    Location:
    Denver, CO
    I've got a new to me 2006 950 Adventure S that appears to be leaking a bit of oil from the gear position sensor. The parts manual for the engine shows an o-ring behind the sensor. Is this something that could be replaced pretty easily during an oil change by pulling the sensor out and putting in a new o-ring? Is the sensor plugged into or attached to anything in the transmission? How does it "sense" gear position? Magnetic? Electronic? Optical?:ear
    #1
  2. cpmodem

    cpmodem Orange Caveman

    Joined:
    Nov 29, 2004
    Oddometer:
    7,130
    Location:
    masa yee yah tee 59° 14' 9" N / 135° 26' 42" W
    You can easily replace the o-ring during an oil change or by leaning the bike over on its right side. It is and electro-mechanical switch with a roller on the end of a spring senses different depth detents for neutral, 2nd, and 3rd gears. It's not plugged into/attached to anything in the trans, but the spring and roller are loose.
    #2
  3. Dogtown

    Dogtown Been here awhile

    Joined:
    Apr 4, 2008
    Oddometer:
    433
    Location:
    Marin County
    Mine was leaking too about a year ago. You can pull the sensor and put in a fresh gasket anytime. You dont need to wait for an oil change. It only holds back a tiny bit of oil. the gasket is 50 cents and it takes 5 mins to swap out. Not sure why these things leak but its a common problem. Always nice to find out its that gasket and not a case crack from the side stand being overloaded!
    Cheers!
    #3
  4. derm75

    derm75 I'm a brother shamus...

    Joined:
    Sep 14, 2007
    Oddometer:
    462
    Location:
    Denver, CO
    Thanks guys! Time to order a gasket. I keep triple-checking that it isn't an engine case. I just received my Black Dog sidestand mount so maybe I can do the o-ring while installing it.
    #4
  5. EastSideSM

    EastSideSM Isn't that dangerous?

    Joined:
    Mar 30, 2008
    Oddometer:
    1,491
    Location:
    Providence, RI
    Had same thing on my SM. Replace o-ring, good to go. Easy fix.
    #5
  6. TA-Zappa

    TA-Zappa Been here awhile

    Joined:
    Nov 9, 2004
    Oddometer:
    173
    Location:
    Ängelholm, Scania, Sweden
    Had a leaking switch to, tried to find a o-ring (the dealer didn't have in stock) that would fit and while unmounting the switch realize that the torque of the bolts are just finger tight. Pull the switch out, clean the o-ring and mount it again. While mounting the switch try to press on the switch while mounting the bolts fingertight and then torque them up.

    I don't have any leaks after that... :)

    If you look at how the bolt holes are threaded I guess you will see the reason, they are only threaded about halfway down... This means that the bolt only have a few threads to grab and the rest is locktite....

    Next time I got a leak I will replace them with helicoil and threaded all the way to the bottom.

    Cheers,
    Zappa
    #6
  7. kzahel

    kzahel Adventurer

    Joined:
    Jan 15, 2011
    Oddometer:
    64
    Location:
    San Francisco, CA
    Found this leak on my '05 950. Going to try and find a gasket and replace without doing oil change...
    #7
  8. sonoran

    sonoran #8645110320 Supporter

    Joined:
    Sep 28, 2009
    Oddometer:
    54,717
    Location:
    33°05'38.7"N 111°40'57.2"W
    No need to drain oil. I replaced my o-ring and it still leaked. A little hi-temp RTV sealed it up nicely.
    #8
    bananu7 likes this.
  9. gozirra

    gozirra Spam?

    Joined:
    Oct 6, 2011
    Oddometer:
    167
    Location:
    tx
    I had the leak, and stripped bolt(s).

    Center stand, remove sensor, plug the sensor hole with shop towels, Heli-coiled, new o-ring, motoseal, win.

    no new leaking.:clap
    #9
  10. Black Hills

    Black Hills Long timer

    Joined:
    Apr 7, 2011
    Oddometer:
    1,924
    Location:
    Western South Dakota
    had the same issue on my 990. replaced the O-ring and it was fine.
    #10
  11. gearheadE30

    gearheadE30 @LC8Adventures

    Joined:
    Jan 20, 2012
    Oddometer:
    2,251
    Location:
    Indiana
    I replaced the oring and it still leaked. Turns out the epoxy seal and had cracked on the back of the sensor. A little JB Weld and I've been good to go ever since. The epoxy was visibly cracked.
    #11
  12. wsmc99

    wsmc99 Been here awhile

    Joined:
    Jan 9, 2004
    Oddometer:
    564
    Location:
    SD, CA.
    Yep same on my SMT.
    Order 2 so you have a spare.
    Quick fix, no draining of oil needed.
    #12
  13. Chuckracer

    Chuckracer Jerkus Maximus

    Joined:
    Aug 26, 2007
    Oddometer:
    10,822
    Location:
    Dexter, NY
    It's a dry sump motor.
    #13
  14. Questor

    Questor More Undestructable

    Joined:
    Oct 8, 2005
    Oddometer:
    4,775
    Location:
    Thousand Oaks, CA.
    I had a leaking O-ring.
    Tried to "just tighten it a bit" and stripped the threads. :becca
    Put in two helicoils and a new factory O-ring and it's better than new.

    I still love these 950's..
    Q~
    #14
  15. snarley

    snarley Long timer

    Joined:
    May 24, 2008
    Oddometer:
    1,040
    can anyone chime in here as to how to do the replacement, whats involved ?

    gotta do it soon

    tks
    #15
  16. tomdubz

    tomdubz getting there Supporter

    Joined:
    Jun 29, 2010
    Oddometer:
    1,350
    Location:
    Your Mom's in RI

    Real simple. Takes more time to remove/replace side-stand and clutch pedal. You'll want locktite on hand for reinstall of those.

    Otherwise:
    -Get to the sensor
    -Remove the sensor
    -Remove/Replace the o-ring
    -Replace the sensor (don't over-torque the small bolts)
    #16
    snarley, Jeff Sichoe and mroddis like this.
  17. RoundOz

    RoundOz Plenty of seasoning

    Joined:
    Jun 10, 2009
    Oddometer:
    2,380
    Location:
    West Nebraska
    My first fix involved a new o-ring plus some oil-proof gasket compound. This lasted maybe 10,000 miles. My second fix necessitated replacing the sensor itself. It appeared to be leaking oil through the wires. Oil was coming out of the plastic sleeve after I cleaned everything up with solvent. I have seen oil migrate through wires many times in the past.

    It was not expensive and made me feel better about a permanent fix.
    This time I used Permatex Permashield (orange tube, not usually sold at auto parts stores so I had to order it in at NAPA) which I bought to try out on my fuel pump in my Safari tank. My last pump install used a different Permatex gasket maker which had mostly dissolved after 10,000 miles.
    In a perfect world you shouldn’t need a sealant for either of these tasks, but my world is far from perfect.
    #17
    nk14zp likes this.
  18. Creekside

    Creekside Been here awhile

    Joined:
    Jun 12, 2013
    Oddometer:
    448
    Yep it’s easy. Have to do one every 20000 miles it seems


    Sent from my iPad using Tapatalk
    #18
  19. hennessyktm

    hennessyktm Still here...

    Joined:
    Apr 9, 2009
    Oddometer:
    251
    Location:
    Munster, Indiana
    Get it fixed? How'd it go?
    Perfect timing with this thread. Mine just started leaking a few days ago. New o-rings ordered.
    #19
  20. bananu7

    bananu7 Been here awhile

    Joined:
    May 14, 2018
    Oddometer:
    160
    Location:
    Gdynia, Poland
    If you want to buy a new O-ring before disassembly, it's 27.5mm x 2.5mm NBR, part number 0770275025.

    The "NBR" material is apparently only good to 100 degrees Celsius. Maybe using something more durable would help for a longer-term fix? Gonna do mine over the weekend.
    #20