Posted by L.A.B. on 11/7/2009, 12:44 pm, in reply to "Gear oil leakage"
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<<do the three potential areas of gear oil leakage warrant a gearbox strip or can they be sorted from behind the clutch?>>
There shouldn't be any need to strip the gearbox to replace either the main output seal or fix a spline leak?
Once the large sprocket retaining nut, tab washer, O-ring and output sprocket are removed, there should be sufficient clearance to get a tool behind the lip of the output seal to hook it out, as the seal actually runs on the machined boss of the sprocket and not directly against the sleeve gear itself.
The output shaft and sprocket splines can be thoroughly de-greased, and smeared with silicone sealant in the area of the O-ring groove (some people like to smear the whole splined area with sealant) re-fit the sprocket and use a new O-ring (do not attempt to re-use old O-ring, even if you do manage to get it out in one piece?).
Removing the mainshaft seal could be more difficult?
While it is possible to remove oil seals from the 'outside' by drilling a couple of small holes in the seal opposite each other, then screwing a couple of self-tapping screws into the holes, and gripping the screw heads with mole grips or pliers to pull the seal out?
However the size and position of the mainshaft seal in relation to the shaft itself makes that almost impossible I would think, and I've never done it that way, so unless another board member knows of an alternative seal removal method with the mainshaft in situ, then the mainshaft will have to be removed to get at the seal?
The chances are that the leak will turn out to be coming from either the output seal or from the sprocket splines?
As the leak appeared to start after you adjusted the primary chain, and if the oil is found to be leaking past the output seal, then I'd suggest you check if there's any noticeable play in the output bearing which could have caused the seal to start leaking?
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