Gearbox leak (continued)

[peels]

Just did my first splitting of the bike(there are 2 threads), half because I wanted to inspect and lube splines, and half due to trans leak right onto the Cat. While apart, I replaced both the input shaft seals. (no oil near clutch, inside seal just done as precaution) Couldn't exactly tell where leak was from so I just replaced them. both. I left the swingarm and final drive connected to the trans during this, removing as one unit.

Well it still leaks. and I still cannot see where its coming from! Actually, I noticed it stopped yesterday. bad sign. Well, it was close to empty as I figured. :/ Refilled, left on center stand...as opposed to usual side stand. there was a 2-3" circle of oil, below the base of the lower control arm-right side of bike. Its apparently leaking onto that arm, and dribbling down. NOTE: On side stand, oil is usually left side of bike, dripping from rear left corner of cat.

It cant really be that input again (that I just replaced), because i THINK it sits above the top level of gear oil while stationary, and should stop leaking. Am I wrong on that? nothing else happening other than the filthy Cat. and embarrassing smoking for a few minutes after shutdown. lol

I think it HAS to be the output shaft seal? BUT. There is NO oil inside the swingarm, as reports would suggest that is the only sign of output shaft seal. I cant find any instances online of gear oil leaking from the output shaft seal, and dripping onto cat. Maybe that driveshaft boot is shot and it leaks there?


I'm sure Ill have to take it apart again -at the swingarm this time though. Just looking for pointers for expediency, before doing that, since it full on riding season, and up time is more important to now. for whatever reason, i'm worried about getting it back together lol.

thoughts? how would one proceed most quickly? thanks!

[towerworker]

My first R ('03) developed precisely the same leak at about 18,000 miles (Summer of 2004) Oddly enough I had changed the tranny oil to synthetic a couple hundred miles prior. Oil was leaking from the output shaft seal onto the cat and burning. At first I could only smell what seemed like burning toast(could not see a leak because it was burning off so quickly). A very slight leak but didn't stay slight long. BMW replaced the output shaft seal under warranty. I haven't run synthetic in my bike(s) since.

[peels]

My first R ('03) developed precisely the same leak at about 18,000 miles (Summer of 2004) Oddly enough I had changed the tranny oil to synthetic a couple hundred miles prior. Oil was leaking from the output shaft seal onto the cat and burning. At first I could only smell what seemed like burning toast(could not see a leak because it was burning off so quickly). A very slight leak but didn't stay slight long. BMW replaced the output shaft seal under warranty. I haven't run synthetic in my bike(s) since.

thanks tower.

I DID find another instance of this online last night. So with your account, that's enough for me. Ill go ahead and order that seal. its only 20$....

and, before you ask. NO! it isn't an antifreeze leak. I checked

[towerworker]

thanks tower.

I DID find another instance of this online last night. So with your account, that's enough for me. Ill go ahead and order that seal. its only 20$....

and, before you ask. NO! it isn't an antifreeze leak. I checked

You beat me to it. That was gonna be my next question.

[peels]

HA!

ordered the seal today. forgot to put it away in the garage, Left on sidestand, it appears it wet the bed last night lol.

8" puddle this morning.

[towerworker]

HA!

ordered the seal today. forgot to put it away in the garage, Left on sidestand, it appears it wet the bed last night lol.

8" puddle this morning.

And I thought it was mostly HD's that left a mark!

My '03 went a couple weeks when the only clue that something was wrong was an unusual burnt toast smell when I'd park it after a ride. No obvious leaks. Then one day I parked it after a ride and I could smell and then hear and see the oil dripping down on the CAT. It got much worse quickly. Bike had about 16-18K on it and I had just previously switched the gearbox to synthetic. Had previously been running Lucas 80/90 gear oil. I don't know what else to blame the leak on but the switch to synthetic.

[peels]

yeah mine started slow like that..... let it go during summer. then waited for winter to look into..

Pretty sure it was caused by many years of sitting, then me buying it and riding it consistently. Particularly that long Arkansas trip last year. Which I noticed the smell and greasy baked cat right after. And long stretch of near and above triple digits.. -long story about a drunken friend, best not told online.


had 13k when i bought it at 11 yrs old- then I doubled that in 3 years. no synth though....

doesn't appear to be too tough a job. Plus i wasn't aware of the pivot bearing issue some have had. <crosses fingers> Ill be starting it next weekend.

[peels]

well after a struggle to locate a 12mm hex key socket in my area, I took it apart last night. The output shaft and boot are bone dry! Think Ill leave it alone. Oil IS coming from behind the slave again. pulled out the rod.. and the little felt washer was tattered! I noticed the edge slightly frayed before, when I had it apart last, but didnt think it was bad enough to cause a leak... Guess I Was wrong. LOL! Also, the input seal I just put in is totally fine.

do you fine folks suppose that tattered felt washer or sleeve, if you will, is enough to cause a pretty decent leak? Noticed also, my "mickey mouse" seal for the slave ripped. My thought is that oil pools up in the tunnel when riding. then I park it on side stand...dripdripdrip slowly through that seal...

Hope the beemer shop has it. otherwise Im waiting til tue or wed for a 5$ part, and bet they ship it in a huge box and charge me more than that part LOL. EDIT: shocking, BMW does not have it, and they wont get it til tuesday. an its a 9 dollar part. :/ lmao

pic of offender:

[peels]

confusing myself. could this actually be the cause? seems unlikely.... now I am wondering if I messed up the seal or the tube!

crap

[towerworker]

I think you found it. If the output shaft and boot are dry then it's not that seal. I don't see what else it could be.

[peels]

I THINK my cause is that I misread the manual, and drove that seal in too far. I think I was reading the directions for a different seal. I just left it in, and added the new one in front of it. if it still leaks..i will abandon hope, and ride it with the leak.

replaced that shift indicator(neutral switch) seal as well. major PITA to get out.

drilled the weep hole for the slave BUT stuck a nipple and a hose on it, so if it leaks again, no smoke or stink. I Will fab up a catch bottle so that I can monitor what if any fluid comes out.

noticed a bit more corrosion on that slave connection...not bad enough to jump out of my seat, but ill have to address that soon too, Im sure. :/

hope to wrap it all up tonight after i mow the lawn. Been so busy. driving me nuts to not have a bike. its been absolutely GORGEOUS out...but I just couldn't handle that stink anymore. Its been so long that i cant remember which pivot pins are which lol.

[peels]

day 2 no leaks so far.

[towerworker]

Great! I've got my fingers crossed for you. Keep us posted.

[peels]

Great! I've got my fingers crossed for you. Keep us posted.

i think were done here.

thanks everybody!