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Old 09-28-2007, 06:52 PM   #1
andrave
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clutch pushrod oil seal on GSXR 750- need help!

My chain broke a while ago, and came forward and broke my sprocket cover, my clutch pushrod, and some other stuff.... I got new parts to replace it and my friend and I managed to get the mangled stock oil seal (the round one that goes around the pushrod) out of the casing, but to my dismay there appears to be no way in the new one is going to fit (it was a real getting the old one out). The service manual shows them using an OEM suzuki tool to press the oil seal in place... it just looks like a punch of some sort, but its hard to tell. Anyway lets just say that the suzuki "Bearing Installation Tool" is definitely not in the budget at this point in time. I have already tried freezing the oil seal and tapping it into place using a like sized socket; no dice, it still seems too large.

Anyone been there and done this before? Any of the shops know how to do it? if so PM me a price...
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Old 09-28-2007, 06:54 PM   #2
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should have hit me up, I had all the parts to fix. I have never had to replace the seal. gl
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Old 09-28-2007, 08:51 PM   #3
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do you mean parts or tools?
I still need it fixed!
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Old 09-28-2007, 09:36 PM   #4
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Old 09-28-2007, 10:27 PM   #5
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Not sure on that bike, but on busas the seal comes from inside engine, must pull and take apart, dealer quoted like 1200 labor and 20 bucks for the seal, so I did it myself, is the seal bigger than the hole? if so not good, why couldnt they use a snapring, that would make too much sense.
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Old 09-29-2007, 02:37 AM   #6
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Yeah the seal is bigger than the hole, but the service manual shows it being removed and inserted through the hole, so I'm guessing its possible for it to be done.
The seal itself is like $5 from Motorcycles Unlimited... and if I have to split the cases I'll just have to drop the engine down enough to get a breaker bar on the bolts, hopefully I can loosen them enough to get the seal in.. hoping someone will chime in that can drive the seal in for me and save me the drama.
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Old 09-29-2007, 08:38 AM   #7
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Quote:
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Yeah the seal is bigger than the hole, but the service manual shows it being removed and inserted through the hole, so I'm guessing its possible for it to be done.
The seal itself is like $5 from Motorcycles Unlimited... and if I have to split the cases I'll just have to drop the engine down enough to get a breaker bar on the bolts, hopefully I can loosen them enough to get the seal in.. hoping someone will chime in that can drive the seal in for me and save me the drama.
Not sure about that, hope it works for U Let me know, curious about it I know that wont work on the busas
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Old 09-29-2007, 06:30 PM   #8
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The engine needs to come out, and the cases will need to be split.
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Old 09-29-2007, 07:11 PM   #9
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For the love of all that is holy.... I hope Patrick can save the seal in mine... he has my bike right now at his shop with the exact same problem but no oil leak afther the chain breakage...

Patrick---->

If that doesn't work I won't get to ride for about 6 months...no money in my budget for that big of a repair. Whick massively sux cause I have only gotten to ride it like 7x since i got it...

Patrick... any chance you can post some pics of the carnage that this caused from my bike to influnce people to maintain their chains/lube, and slack.
this could have been an injury to me had it happened at high speed... luckly I was going like 40mph.
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Old 09-29-2007, 08:12 PM   #10
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I'll post some next week when we get back in.
I looked at it again and I think I can salvage it, I'll know more once I get the new parts and get it back together. Keep your fingers crossed!
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Old 09-29-2007, 09:57 PM   #11
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I had some damage to the threads on the lower engine case as well so I'll probably just pull the engine and replace the case.
sucks but at least its do-able.
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Old 09-29-2007, 10:23 PM   #12
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I am {fingers crossed}. and....andrave.. I feel ur pain.
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Old 09-29-2007, 10:30 PM   #13
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Been there done that with a badass chain, was at the dragstrip when it snapped, broke water pump , dumped hot coolant, oil and clutch fluid on my left leg and tire on a 10,000 rpm launch, ouch, had to pull engine because of this seal, poor design, coulda been held in with a snapring and would be a 10 minute job, but nooo, had to put it in from inside, I think its because of high oil pressure there?
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Old 09-29-2007, 11:27 PM   #14
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Quote:
Originally Posted by Sprayboy91 View Post
For the love of all that is holy.... I hope Patrick can save the seal in mine... he has my bike right now at his shop with the exact same problem but no oil leak afther the chain breakage...

Patrick---->

If that doesn't work I won't get to ride for about 6 months...no money in my budget for that big of a repair. Whick massively sux cause I have only gotten to ride it like 7x since i got it...

Patrick... any chance you can post some pics of the carnage that this caused from my bike to influnce people to maintain their chains/lube, and slack.
this could have been an injury to me had it happened at high speed... luckly I was going like 40mph.



Push rod seal? Is that the one behind the front sprocket or the seal between the slave cylinder and the pushrod? I would assume the latter. I got lucky myself....I too had a chain snap under "semi-heavy" throttle. Lucky for me, the only damage was a few hours of time to replace the tranny cover and chain/sprocket. Good luck man.

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Old 09-29-2007, 11:29 PM   #15
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The one under the clutch slavefor the clutch pushrod, countersprocket seal is easy
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Old 09-29-2007, 11:39 PM   #16
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Quote:
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The one under the clutch slavefor the clutch pushrod, countersprocket seal is easy
thanks bubba....
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Old 09-30-2007, 01:51 AM   #17
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Yeah the one right in front of the sprocket, its like a washer that fits in behind a groove and its got a spring that holds tension around the pushrod itself.
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Old 10-01-2007, 06:51 PM   #18
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Wow, is it leaking clutch pushrod seal week or something? My bike is at Motorcycles Unlimited for the same!
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Old 10-01-2007, 08:22 PM   #19
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When chains snap on suzukis, yep I think they make a guard for that I,m telling ya its a poor design, but what ya gonna do?
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Old 10-01-2007, 10:13 PM   #20
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its a horrible design... does anyone make a guard for it?

I'm going to have to remove the engine and split the case, and do so some other damage to the lower case I'm gonna go ahead and swap out the case.
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