I’ll try to make this short, but…………
While on our recent 50 day cross-country, I developed a nice little leak out of the Shift Shaft Seal on our 2014 SGS. Had close to 95k on the bike at the time. Not a bad leak and it would wait till we got back. After we got back, I went in to replace the Seal, as well as install a new Dark Horse Man-o-War Motor Sprocket that I’ve been wanting. (see other thread I started on that). Anyhow, taking the suggestions of multiple people, I decided to use the smallest little wood screws I could find in my shop to remove the old leaky seal. Well, it apparently got crooked while screwing it in and left a nice not so little gouge in the sidewall of the bore in the Tranny Housing that the seal fits into. See pic below……
So what I’ve done to this point is, on the 1st attempt I lightly sanded the extruding burr off the damaged area, crossed my fingers and put a new seal in. Fail……
Next time I took a little dab of the Permatex Gasket Dressing (Hylomar Blue) that I had, right on the gouge, crossed fingers. Fail…..
Next time, after replacing the Shifter Mechanism Shaft that the seals ID rides on with a new one, (thinking it was worn/grooved/scratched), I took the same sealant, put some extra on the gouge and also lightly all around the the rest of the bore. Fail……
This last time I gooped the sealant all around the bore pretty good, but not too much, installed the seal, let it set up for a few hours, then reassebled everything and let it sit overnight. Better, but still fail…..
This is the sealant I’ve been using and I’m beginning to think maybe it’s not the right stuff…….
So, I’m at the point where I can go back in and try it ONE LAST TIME before I either have to buy a whole new Tranny Case, ($600!), or take mine to the local Machine Shop and have my buddy do a “Bore and Sleeve” to repair what I phucked up. However……… I’m really thinking I can fix this with a different type sealant…… I think this stuff I’ve been using is too soft. What do you guys suggest as far as what sealant I can/should use to seal this? I REALLY don’t want to pull the Tranny out for either repair or replace. There has to be a better sealant that I can use for this that will work, right? I have this other stuff, but I’m not too sure about that either. I’d rather hear from you guys first………..
On a side note, I’m getting really fast at tearing this thing down and putting it back together again, lol!! Plus, I found a great way to remove the seal without drills and screws. Just take the Tranny Cover off and push the Shifter Mechanism back into the Tranny and it gets the Shift Shaft out of the way so you can pop the seal right out! (see the top pic again) I love YouTube!!