shift shaft oil seal replacement

lolibater · September 11th, 2012, 09:59 PM

Does anyone have any pointers or a how to on this? As of right now, I'm just assuming remove the shift linkage, remove the front sprocket cover, and remove the old seal with a dental tool? Any hints to make it easier?

Also, are there any places on the engine that have common oil leaks? Is a very small oil leak "acceptable?" I am very new to bikes in general, so any info you could provide on this will be helpful. Thanks.

Alex · September 14th, 2012, 09:23 PM

Maybe some tips here:

http://www.ninjette.org/forums/showthread.php?t=98723

Motofool · September 15th, 2012, 10:47 AM

Make sure that there is an actual leak.

Sometimes, excess of chain lubrication lands on and drips from that area.

lolibater · September 15th, 2012, 11:49 AM

Its an actual leak. 100% sure.

Motofool · September 15th, 2012, 11:51 AM

Then, the procedure that you describe is correct.

Just make sure that the shaft doesn't have sharp dents that could damage the inner lip of the seal.

Any defect can be flatten with a file.

Also use some lubrication over the shaft.

lolibater · September 23rd, 2012, 08:09 AM

Tried replacing this yesterday. Came across an issue:

The water pump is making the seal inaccessible. In the top picture you can see where the one bolt kind of goes over the left hand side of the seal. The bottom picture, showing how it's clear on the right side for comparison. The few walkthroughs and how to videos that I have watched are for similar motors, not this one in specific. Of course all of them don't have a water pump housing that goes over the shift shaft.

Will I have to split the case for this?

Motofool · September 23rd, 2012, 08:18 AM

No, just lean the bike toward the right, so the oil level clears the pump opening in the crankcase.

Disconnect the pump tubing and just pull it out.
The pump shaft will slide out from the coupling.
A new pump-crankcase seal may be necessary.

Are you sure of not being able to pull the old seal without removing the pump?

lolibater · September 23rd, 2012, 08:22 AM

So in the top picture, I disconnect the 5? bolts to the left of the shift shaft and then pull the water pump away from the bike?

Motofool · September 23rd, 2012, 08:27 AM

Are you sure of not being able to pull the old seal without removing the pump?

Check these threads:

http://forums.ninja250.org/posting.p...&t=88025&tro=1

http://forums.ninja250.org/posting.p...&t=86472&tro=1

http://forums.ninja250.org/viewtopic...b8dbd52754cd72

lolibater · September 23rd, 2012, 09:08 AM

Reading through those threads......

doesn't seem really related to this at all though. At least no mention of removing the shift seal without removing the water pump.

Motofool · September 23rd, 2012, 10:07 AM

Sorry, I couldn't find any info specific to your case.

However, those threads show that the pump can be simply pulled out and that some seals can be very hard to remove.

lolibater · September 23rd, 2012, 10:14 AM

Based on what you read in there, does it seem that I should be able to remove the pump without having to drain oil or coolant?

alex.s · September 23rd, 2012, 10:31 AM

Seems like it would be easier removing the shift shaft first then you could slide a small puller and extract the seal in a few seconds. But I guess that's a lot of work

alex.s · September 23rd, 2012, 10:34 AM

Quote:

Originally Posted by lolibater

Based on what you read in there, does it seem that I should be able to remove the pump without having to drain oil or coolant?

You will need to dump the coolant if you drop the pump. Might as well drop the oil if you are going g to be removing engine components... If it's new oil use a clean container and reuse it

lolibater · October 10th, 2012, 02:08 PM

This thing was such a bitch to get out. Here is the aftermath:

alex.s · October 10th, 2012, 02:17 PM

what did you do to get it out

lolibater · October 10th, 2012, 02:24 PM

drained coolant, removed the water pump, removed the shifter, removed the front sprocket cover.

broke off 2 dental tools, bent 3 hook tools from autozone, broke a chisel. FInally got it out by heating it up and using a punch to blow like 20 holes in it before it just came out mangled.

The instructions had a single sentence; "Pry old seal out."

Yeah it's not that easy. Especially since the picture of the one they "removed" looks brand new.

alex.s · October 10th, 2012, 02:32 PM

did you remove the external shift shaft as well as the shifter linkage itself? did you have to take off the right side clutch cover?

lolibater · October 10th, 2012, 04:17 PM

We did not take of the actual shift shaft, no. Just the shift linkage. One bolt.

We did not take of the clutch cover either.

lgk · October 10th, 2012, 04:20 PM

dang son, you beat the piss out of that bushing, lol.

lolibater · October 10th, 2012, 04:22 PM

yeah we messed that thing up so bad. We were asking the neighbors for all kinds of crazy things trying to get it out. Some of them are into bikes, and started gathering outside our garage with @138. It basically turned into a spectator sport for them.

Finally we got that **** out and everyone was cheering lol.

September 11th, 2012, 09:59 PM	#1
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	shift shaft oil seal replacement Does anyone have any pointers or a how to on this? As of right now, I'm just assuming remove the shift linkage, remove the front sprocket cover, and remove the old seal with a dental tool? Any hints to make it easier? Also, are there any places on the engine that have common oil leaks? Is a very small oil leak "acceptable?" I am very new to bikes in general, so any info you could provide on this will be helpful. Thanks.

September 14th, 2012, 09:23 PM	#2
Alex ninjette.org dude Name: 1 guess :-) Location: SF Bay Area Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much. Blog Entries: 7	Maybe some tips here: http://www.ninjette.org/forums/showthread.php?t=98723 __________________________________________________ Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered)

September 15th, 2012, 10:47 AM	#3
Motofool Daily Ninjette rider Name: Hernan Location: Florida Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot. MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16	Make sure that there is an actual leak. Sometimes, excess of chain lubrication lands on and drips from that area. __________________________________________________ *Motofool* *.................................Never ride faster than your guardian angel can fly* "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí

September 15th, 2012, 11:49 AM	#4
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	Its an actual leak. 100% sure. __________________________________________________ "The enemy is fear. We think it is hate, but it is fear." - Gandhi

September 15th, 2012, 11:51 AM	#5
Motofool Daily Ninjette rider Name: Hernan Location: Florida Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot. MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16	Then, the procedure that you describe is correct. Just make sure that the shaft doesn't have sharp dents that could damage the inner lip of the seal. Any defect can be flatten with a file. Also use some lubrication over the shaft. __________________________________________________ *Motofool* *.................................Never ride faster than your guardian angel can fly* "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí

September 23rd, 2012, 08:09 AM	#6
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	Tried replacing this yesterday. Came across an issue: The water pump is making the seal inaccessible. In the top picture you can see where the one bolt kind of goes over the left hand side of the seal. The bottom picture, showing how it's clear on the right side for comparison. The few walkthroughs and how to videos that I have watched are for similar motors, not this one in specific. Of course all of them don't have a water pump housing that goes over the shift shaft. Will I have to split the case for this? __________________________________________________ "The enemy is fear. We think it is hate, but it is fear." - Gandhi

September 23rd, 2012, 08:18 AM	#7
Motofool Daily Ninjette rider Name: Hernan Location: Florida Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot. MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16	No, just lean the bike toward the right, so the oil level clears the pump opening in the crankcase. Disconnect the pump tubing and just pull it out. The pump shaft will slide out from the coupling. A new pump-crankcase seal may be necessary. Are you sure of not being able to pull the old seal without removing the pump? __________________________________________________ *Motofool* *.................................Never ride faster than your guardian angel can fly* "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí

September 23rd, 2012, 08:22 AM	#8
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	So in the top picture, I disconnect the 5? bolts to the left of the shift shaft and then pull the water pump away from the bike? __________________________________________________ "The enemy is fear. We think it is hate, but it is fear." - Gandhi

September 23rd, 2012, 08:27 AM	#9
Motofool Daily Ninjette rider Name: Hernan Location: Florida Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot. MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16	Are you sure of not being able to pull the old seal without removing the pump? Check these threads: http://forums.ninja250.org/posting.p...&t=88025&tro=1 http://forums.ninja250.org/posting.p...&t=86472&tro=1 http://forums.ninja250.org/viewtopic...b8dbd52754cd72 __________________________________________________ *Motofool* *.................................Never ride faster than your guardian angel can fly* "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí

September 23rd, 2012, 09:08 AM	#10
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	Reading through those threads...... doesn't seem really related to this at all though. At least no mention of removing the shift seal without removing the water pump. __________________________________________________ "The enemy is fear. We think it is hate, but it is fear." - Gandhi

September 23rd, 2012, 10:14 AM	#12
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	Based on what you read in there, does it seem that I should be able to remove the pump without having to drain oil or coolant? __________________________________________________ "The enemy is fear. We think it is hate, but it is fear." - Gandhi

September 23rd, 2012, 10:31 AM	#13
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	Seems like it would be easier removing the shift shaft first then you could slide a small puller and extract the seal in a few seconds. But I guess that's a lot of work __________________________________________________

October 10th, 2012, 02:08 PM	#15
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	This thing was such a bitch to get out. Here is the aftermath: __________________________________________________ "The enemy is fear. We think it is hate, but it is fear." - Gandhi

October 10th, 2012, 02:17 PM	#16
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	what did you do to get it out __________________________________________________

October 10th, 2012, 02:24 PM	#17
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	drained coolant, removed the water pump, removed the shifter, removed the front sprocket cover. broke off 2 dental tools, bent 3 hook tools from autozone, broke a chisel. FInally got it out by heating it up and using a punch to blow like 20 holes in it before it just came out mangled. The instructions had a single sentence; "Pry old seal out." Yeah it's not that easy. Especially since the picture of the one they "removed" looks brand new. __________________________________________________ "The enemy is fear. We think it is hate, but it is fear." - Gandhi

October 10th, 2012, 02:32 PM	#18
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	did you remove the external shift shaft as well as the shifter linkage itself? did you have to take off the right side clutch cover? __________________________________________________

October 10th, 2012, 04:17 PM	#19
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	We did not take of the actual shift shaft, no. Just the shift linkage. One bolt. We did not take of the clutch cover either. __________________________________________________ "The enemy is fear. We think it is hate, but it is fear." - Gandhi

October 10th, 2012, 04:20 PM	#20
lgk ninjette.org certified postwhore Name: Jason Location: Norfolk, VA Join Date: Dec 2011 Motorcycle(s): 2012 EX250, 2014 EX300 Posts: A lot.	dang son, you beat the piss out of that bushing, lol. __________________________________________________ Ethioknight Memorial Fund- Sticker sale http://www.ninjette.org/forums/showthread.php?t=111700

October 10th, 2012, 04:22 PM	#21
lolibater ninjette.org certified postwhore Name: Rick Location: Napa, CA Join Date: Sep 2012 Motorcycle(s): 2005 ZX6R, 2011 Sprint GT Posts: A lot.	yeah we messed that thing up so bad. We were asking the neighbors for all kinds of crazy things trying to get it out. Some of them are into bikes, and started gathering outside our garage with @138. It basically turned into a spectator sport for them. Finally we got that **** out and everyone was cheering lol. __________________________________________________ "The enemy is fear. We think it is hate, but it is fear." - Gandhi

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