Gearbox oil in flywheel housing

[Scout63]

My G5 is leaking gearbox oil from the timing inspection hole.  I know it’s gearbox oil since it is pink Redline Shockproof. I can’t believe that this is normal. It must be coming in from the input shaft. Am I ok to run the bike in this condition?  I’m not quite ready to crab the frame again quite so soon.

[nc43bsa]

Check to make sure the gearbox is not overfilled.

If it has the proper oil level, line up your tools and prepare to do some crabbin' again.

[John A]

With any luck at all, it’ll be the clutch pushrod seal. The original is two cone shaped seals. The better one is a stack of o rings. Access is from the back after the swing arm is removed. The smart guys will be along shortly to ‘splain  it or search on this should be good

[Old Jock]

Jeez Scout you're not having much luck these days are you, first the charging system now this 

I've not heard of Redline making it past the seals before, I too use the Shockproof Heavy and so far no problems, I don't doubt rodekyll, just saying it has not been my experience to date.

As the others have said overfill and pushrod seals checked first as you'd be proper p*****d if you crabbed and either of these were the problem. I'd also check to ensure your breather line isn't blocked or kinked, that would pressurize the box and push oil to where it's no right to be.

You got my gearbox article, not that's it's brilliant or anything, far from it but it does give you some ideas of how the box works and where the oil is and isn't?

Worst case it's the Clutch shaft (input) seal, not expensive but I PIA to get to

John

[Scout63]

Hopefully it’s the oil level.  I just installed the pushrod oil rings.  There was some oil coming out the breather earlier and I fitted a hose from that to the rear.  Maybe it forced the oil forward. I’m not overly concerned. Worst case scenario I crab it again.  I’ve gotten pretty fast at it.

[Ncdan]

I had the same issue with my 02 Stone when u first hit it last year.
I changed the fluid to be sure the amount was right and went to a heaven lube. This ended my minor leak.

[Chuck in Indiana]

Hopefully it’s the oil level.  I just installed the pushrod oil rings.  There was some oil coming out the breather earlier and I fitted a hose from that to the rear.  Maybe it forced the oil forward. I’m not overly concerned. Worst case scenario I crab it again.  I’ve gotten pretty fast at it.

Worst case is it fouls the new clutch plates, and you get to buy new ones again. 

[Scout63]

I’ve been looking at parts diagrams and have a sneaking suspicion that I didn’t install the clutch hub seal on the front of the gearbox. I’ll tear it apart again.  I ordered new clutch plates as I’m sure the current ones will be fouled. I’ll report back in a few weeks.

[centauro]

I’ve been looking at parts diagrams and have a sneaking suspicion that I didn’t install the clutch hub seal on the front of the gearbox. I’ll tear it apart again.  I ordered new clutch plates as I’m sure the current ones will be fouled. I’ll report back in a few weeks.

I had the issue on my SP a couple of years back, and realized that it was my fault; when I replaced the gearbox input shaft seal, I inserted it too far in. It needs to be flush with the front flange surface, so that the clutch gear hub covers the seal lips when fully inserted. Also, there are 2 different size o-rings that go over the front of the input shaft that should be replaced and carefully installed to prevent rolling off when the clutch hub is inserted. Doing all of the above completely cured the issue.

[acguzzi]

if it were the pushrod seal Iwould expect it was already on your clutch plates giving you grief, most likely its the output seal