Cam Phase Sensor O-Ring Size- trick question, it is not an o ring

[Orange Guzzi]

Doing some Spring cleaning on my 2003 hydro motor and got to the leaking oil from the cam phase sensor.  I removed the sensor, shim and o ring.  the o ring was just a ring and rubber, on "o" about it.  I pulled out my 3 boxes of o ring assortments and looked for a suitable replacement.  Nothing I have works.  I then did some measuring.  The depth of the pocket in the cam cover is to deep for an o ring to compress against the shim/flange.  The pocket is 2.5 mm deep.  If I use a o ring with a cross section diameter of 2.5 mm, the over all outside diameter when installed on the phase sensor is to large to fit in the hole.  I have not seen a new/good o ring.  These findings lead me to believe it is not a true o ring, rather a rubber sleeve/tube that fits in the pocket. 

sensor diameter 15 mm + (2 x 2.5 mm cross section of a 0 ring) = 19 mm.  The I.D. of the pocket is 17.5 mm.  The depth of the pocket, 2.5 mm. 

My temporary fix was to place 2  1.6 mm cross section o rings on the sensor and some Honda bond before installing.  This gave me a  tight fit around the sensor and stacked high enough to compress slightly when the screws are tightened.

If an o ring is suppose to go in the pocket and seal, at least on my bike, it never will fit or seal properly.  What say you all? Is it truly an o ring or a special seal ring?

[RinkRat II]

  Your spot on O G. It was a sleeve on my sport. Went the double o-ring route on mine and it's not leaked in a year.

    Paul B

[balvenie]

The original "seal" does not work.  I too, could find nothing to replace it. Cleaned everything with acetone and applied ThreeBond and that fixed the leak. I wonder what that "seal" is for? Mine started leaking almost from new.

[Orange Guzzi]

I did some measuring, some searching, some ordering and some tool making over the last few days.  I have come up with/made a seal that fits the phase sensor and crankcase hole. 

I have a couple on my work bench available for testing.  I placed one in my bike with out sealant and went for a ride.  No leak. 

Let me know if you want to be a tester of prototypes.  I will drop one in an envelope and mail it out.   

[Dean Rose]

I did some measuring, some searching, some ordering and some tool making over the last few days.  I have come up with/made a seal that fits the phase sensor and crankcase hole. 

I have a couple on my work bench available for testing.  I placed one in my bike with out sealant and went for a ride.  No leak. 

Let me know if you want to be a tester of prototypes.  I will drop one in an envelope and mail it out.

Send me an email and I'll give you my mailing address for one of those to fit my EV.

Dean

[dguzzi]

I'll volunteer too. This is for the cam position sensor correct? Oh I see they do call it the Phase Sensor, odd to me...
  I guess I won't mess with it, its not leaking.  Do you suppose something like rubber handle dip stuff would work for that; if it had time to cure?  By golly it is weeping and a little wet around there!  Thanks Orange!