To all-

New to the forum as a user but I've been a creeper for the last 8 months since I bought my first bike at the age of 31. Since then I have become a full on moto nerd and I absolutely dig everything about this sport.

Here's my issue- I'm getting my bike out from storage this year and notice a minor leak coming from the inside of the shaft of the shifter. It's not decimating oil levels but I am concerned. My assumption is there must be a washer/gasket that could be the issue? Am I way off base?

Pictures are hopefully below.

Is this a known issue?
Is it something I can do myself?
Anyone know a part # I need?

Thanks in advance...!

That hole in the end of the shifter shaft is probably nothing more than to save weight. There's no seal for the center of the shifter shaft, just the outside. On the other side of the shaft inside the right side cover, there's a flat piece of steel that's welded to the shaft which actuates the shift drum. Unless that weld is bad and leaking oil into it or the shaft is that worn beyone belief, there should be any oil coming out of there. I would clean it out and see if it continues. I wouldn't lose any sleep over it even if it did leak a little.

Thanks Charlie... Good to know whats "inside".

Would there be anything above this piece on the bike that could be dripping down?

I cleaned it pretty good yesterday and plan on checking it tonight. Appreciate your input and time.

Thanks

Ok- Thanks to your advice I eliminated the leak from the actual shaft- Oil was actually dripping down onto the shifter and at the angle the bike was at (due to the triangle) it made it appear like the leak was actually coming from the shaft. It is not.

Oil is leaking down from the front sprocket area. I got under the bike last night and was able to find a droplet of oil collecting onto one of the chain links. This link was on the lowest to the ground front sprocket tooth.



This is the under side view of the oil droplet:


Here is the trail the oil was taking causing the "phantom" shifter leak:


Now what am I up against? Have I learned something new here? Common problem? Most importantly- SOLUTION?

On the plus side- After sitting all winter the bike has fired twice now with relatively little effort (from what I understand from these forums and personal experience they are notoriously hard to start when cold)
Mega Plus- I took it for the first ride of the year (If you count back alleys and around my block). Cant wait for a real rip..

It's most likely your countershaft seal (part #35 below), which is an easy fix.  If you have the time, confirm that its actually coming from the seal by removing both the chain and sprocket and clean the area thoroughly with degreaser.  After it's been sitting over night check to see if the oil is coming from the countershaft seal. If it is the seal, remove the collar (part #3) and gently pry out the old seal and replace with a new one.  When removing the seal be careful not to damage the d-ring (#36) which will remain on the countershaft.

Awesome! Thanks for the tips.

I'll get on this over the weekend!

Ok- I've got everything open and the oil leak is coming from the counter shaft seal- how do I pull the collar off?

haha i had to comment. I like the little arrows showing the leaks

Abovethewake, on 08 April 2012 - 12:33 PM, said:

Pull it straight out using a pair of adjustable pliers. With the sprocket removed, the only thing holding it in is the lip of the seal.

Ok- I'm steps away from taking this to someone who knows what they're doing but I don't want to give up on myself just yet.

I have the new Countershaft seal and I understand that I should be able to pull the collar out with pliers BUT so far the force required has eluded me. I have tried a pair of vice grips and channel locks and can't get it to budge.

2 things- Am I correct in identifying the two parts and second- If it's not budging should I try something else or is this another new issue?

Thanks again for all the help...

Here's a few more arrows...

Abovethewake, on 10 April 2012 - 10:17 AM, said:

Yep, those are the correct parts and it should pull right out.  Will the collar spin at all?  The collar just slips onto the output shaft, although there could be some corrosion between the two holding it on tight.

BTW I like your pics and arrows    What is typed out in a forum and how it's translated by others often times is completely different.

If you need that much force on the collar, I would recommend replacing it, and not worry about damaging it.  Also, I would replace both the seal AND the D-ring.  The D-ring is pretty inexpensive if memory serves me correctly.

Just thought I would provide an update- I took the bike into a local mechanic and had him take over as I was not equipped with the tools/knowledge to go forward.

He ended up having to die grind the collar to get some purchase on it and eventually got it free. There was a bit of a build up of grass in there but he was not really able to give me an answer as to why/how it would have ended up on there with such force.

At the end of the day he got it off, replaced all three parts (collar, and both seals) and the bike is running awesome. Been out on it a few times and no follow up issues at this time.

Thanks for everyone's help on this one! Really appreciate the advice... Hoping if there is a next time it will slide off as easily as everyone said it should.

Cheers!

Here's the collar after removal:

Glad to see you got it fixed, I've never seen one that took that much effort to remove!