Drewman Posted June 21, 2014 Share #1 Posted June 21, 2014 (edited) I took off the middle gear cover and found a couple of oil leaks. (see attached pictures) The grommets around the wire bundles coming out of the engine case appear to be leaking. I lifted up the two wire bundle up to move them out of the way and oil poured out of the wire casing. I plan on cleaning with break fluid and sealing with high temp RTV. Second leak is from the oil seal around the shifter shaft shown in the second picture. I just got that linkage off and am trying to pull out the seal. I turned in a couple of small screws and used small vise grips on both screws at the same time but no luck. Any suggestions on how to get the seal out? I might cut it but don't want to nick the shaft or housing. Drewman Edited June 21, 2014 by Drewman Link to comment Share on other sites More sharing options...
Venturous Randy Posted June 21, 2014 Share #2 Posted June 21, 2014 I plan on cleaning with break fluid and sealing with high temp RTV. Drewman You plan on cleaning with brake fluid? RandyA Link to comment Share on other sites More sharing options...
Drewman Posted June 22, 2014 Author Share #3 Posted June 22, 2014 (edited) Sorry ....brake cleaner Edited June 22, 2014 by Drewman Link to comment Share on other sites More sharing options...
Drewman Posted June 22, 2014 Author Share #4 Posted June 22, 2014 Attached is a picture of the oil seal around the shifter shaft. Anyone taken one of these out before? I tried two screws 180 degrees apart and pulling it out but it wouldn't budge. I tried cutting it with a knife but the blade would not penetrate. I tried tapping a small screw driver into the seal 90 degrees apart 4 places. Seal still wouldn't pull out. I imagine if I keep trying eventually it will come out. Just wondered if anyone else has changed one and if so, how did you get it out. Thanks, Drewman Link to comment Share on other sites More sharing options...
MasterGuns Posted June 22, 2014 Share #5 Posted June 22, 2014 IMO, the screws you are using are too big. Try using two much smaller screws. Insert them in another location so as to get a good tight fit. Link to comment Share on other sites More sharing options...
dvuch1 Posted June 22, 2014 Share #6 Posted June 22, 2014 OMG is that the only way to get it out? Somebody help this guy!! Mines leaking too and I need an easier way. Link to comment Share on other sites More sharing options...
stanG Posted June 23, 2014 Share #7 Posted June 23, 2014 I'm thinking a couple of mechanics picks with short right angle bend slipped in next to the shaft then turned to get a grip from behind. Not enough clearance for a regular seal puller. Link to comment Share on other sites More sharing options...
Drewman Posted June 23, 2014 Author Share #8 Posted June 23, 2014 Thanks! I tired that but I just stuck it into the rubber in the middle of the seal. No luck. I will try going down the side of the shaft. Link to comment Share on other sites More sharing options...
Peder_y2k Posted June 23, 2014 Share #9 Posted June 23, 2014 ........ sealing with high temp RTV. Sorry, that does not work. Need to replace rubber grommet with new.....OR..... shim the inside of the grommet around each wire and then seal with RTV. Shrink tubing could be used as a shim. Do it right, or do it over -Pete, in Tacoma WA USA Link to comment Share on other sites More sharing options...
Drewman Posted June 23, 2014 Author Share #10 Posted June 23, 2014 To replace does that means an engine teardown since I would have to replace the whole wire bundle? I don't think just the grommet is available. Link to comment Share on other sites More sharing options...
stanG Posted June 23, 2014 Share #11 Posted June 23, 2014 Another option as a last resort would be to pull the cover off on the other side, remove the shaft and then pull it out. Link to comment Share on other sites More sharing options...
Peder_y2k Posted June 23, 2014 Share #12 Posted June 23, 2014 To replace does that means an engine teardown since I would have to replace the whole wire bundle? I don't think just the grommet is available. Engine generator cover must be removed for servicing the grommet. OK...Since the grommet is not available, one would cut the 3 white generator wires at the connector, then work them out of the grommet. Then clean the wires and grommet with carb/brake cleaner and also the grommet seat areas. Once clean, use shrink tubing properly applied to the wire where it would pass thru the grommet and work the wire back into the grommet. The shrink tubing makes a tighter seal for the wire. Once all is back in place, seal the wires on both sides with high temp oil resistant RTV ....just enough to cover. When assembling the side cover back on the engine, use the same RTV to seal the grommet to the engine and cover. Replace the wire connector with either soldered connections (best), or use a screw terminal block with soldered wire terminals. Don't use any push connectors. -Pete, in Tacoma WA USA Link to comment Share on other sites More sharing options...
camos Posted June 24, 2014 Share #13 Posted June 24, 2014 Engine generator cover must be removed for servicing the grommet. Yes. OK...Since the grommet is not available, one would cut the 3 white generator wires at the connector, then work them out of the grommet. Then clean the wires and grommet with carb/brake cleaner and also the grommet seat areas. The wires don't need to be cut. Once the cover is off the grommet will lift out of its slot and the wires can be worked through the holes so they can be cleaned. Put RTV on the wires and pull a bit past where they originally were. Add more RTV and slide them back to original position. Put a dab of RTV around the slot before putting the grommet back in and some more on the outside edge to seal to the cover. This method worked for me when I replaced a stator that did not come with a grommet. Link to comment Share on other sites More sharing options...
Drewman Posted June 26, 2014 Author Share #14 Posted June 26, 2014 What cover is the engine generator cover? Is it the one forward of the middle gear cover with the 1300cc on it? By the way I finally got the shaft oil seal out tonight with a slide hammer with a small screw in the end of it Link to comment Share on other sites More sharing options...
Peder_y2k Posted June 26, 2014 Share #15 Posted June 26, 2014 That's the one.. -Pete, in Tacoma Wa USA Link to comment Share on other sites More sharing options...
Drewman Posted July 13, 2014 Author Share #16 Posted July 13, 2014 Anything I need to know about getting that cover off? Does the gear shift have to be taken completely off? Link to comment Share on other sites More sharing options...
jasonm. Posted July 13, 2014 Share #17 Posted July 13, 2014 (edited) Engine generator cover must be removed for servicing the grommet. OK...Since the grommet is not available, one would cut the 3 white generator wires at the connector, then work them out of the grommet. Then clean the wires and grommet with carb/brake cleaner and also the grommet seat areas. Once clean, use shrink tubing properly applied to the wire where it would pass thru the grommet and work the wire back into the grommet. The shrink tubing makes a tighter seal for the wire. Once all is back in place, seal the wires on both sides with high temp oil resistant RTV ....just enough to cover. When assembling the side cover back on the engine, use the same RTV to seal the grommet to the engine and cover. Replace the wire connector with either soldered connections (best), or use a screw terminal block with soldered wire terminals. Don't use any push connectors. -Pete, in Tacoma WA USA Don't do what you are suggesting. Your shrink tubing idea is just another wicking thing. ALL YAMAHAs from the 80's develope a slow leak at the wires. It's the wires exterior protection WEAVE that acts as a WICK and draws the oil out. You can again and again spray with brake cleaner. And use ONLY permatex ultra black or grey globbed in and around the wires. ME... outside of the generator cover I completely and carefully removed the outside weave insulation then the inner rubber insulation and separated the wires then put lots of permatex. Permatex ultra RTV is the best and strongest insulator. Let it sit 24hours. If you have Suzuki dealer near. They sell a Suzuki brand RTV black and grey. Also very good. I like black. Mine leaks maybe a tablespoon every 3000 miles. Parking it overnight on the center stand helps too. Yes, the gear shift assy. needs removal. But taking the generator cover off for this leak by replacing the grommets .....it won't fix it. As long as you have braided jacket wire insulation it can leak. Edited July 14, 2014 by jasonm. Link to comment Share on other sites More sharing options...
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