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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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Old 27th December 2016
sapper3858 sapper3858 is offline
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Default Shifter Shaft Seal Replaced and Still Leaking

I have replaced my shifter shaft seal twice now. The first time I did it myself and the second time by the shop. It is still having a slow leak. What are my next steps in trouble shooting. I have researched and can't find a solid answer. I have my clymer manual and I'm leaning toward replacing the shifter shaft next. It is on a 2005 1200 custom.
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  #2  
Old 27th December 2016
semjpm semjpm is offline
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Put tape over the shaft and the splines when slipping the new seal on.

SEMJPM
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Old 27th December 2016
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You might compare the '05 to the '06 seals as I believe they are different (just in case)
You also have the rubber seal on the outside ?
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Old 27th December 2016
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I cured my issue by simply adding an additional o-ring in front of the seal behind the shifter, seems like the extra compression is what it took for me.
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Old 27th December 2016
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Quote:
Originally Posted by semjpm View Post
Put tape over the shaft and the splines when slipping the new seal on.

SEMJPM
Thanks for the tip but I did that intitally when I installed it myself.
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Old 27th December 2016
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Quote:
Originally Posted by sportsterpaul View Post
I cured my issue by simply adding an additional o-ring in front of the seal behind the shifter, seems like the extra compression is what it took for me.
Hmmm. Do you mean putting the new seal on first and then and o-ring, or do you mean o-ring and then the new seal? I think you mean instal seal and then o-ring. If seal first and then o-ring, I will give that a try tomorrow.
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Old 27th December 2016
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Quote:
Originally Posted by rocketmangb View Post
You might compare the '05 to the '06 seals as I believe they are different (just in case)
You also have the rubber seal on the outside ?
The seal I bought from Harley looked like just rubber, but the seal my buddy's shop put in looks like it has some brass or a type of metal in it. I'm not sure if that is the difference but I will do some more research. As far as the rubber seal on the outside do you mean that thick rubber piece that is in between the shifter lever and the actual shifter shaft seal. If so, from what I have read and been told it's just basically a rubber spacer and does nothing to contribute to sealing oil inside the primary. Thanks for the info tho man. I'm pretty sure I'm going to have some more questions for you kind sir. I am doing some engine mods now and really like what you have listed in your signature minus the royal purple haha. I'm an amsoil guy myself but to each their own.
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Old 27th December 2016
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Hey sapper !
I assume if its a rubber part its some type of seal even if just to keep dust out of the actual seal.
I'm sure the 04-05 seal is different from the '06 but I am guessing if you had a late production '05 it could have the '06 cover which is different.
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Old 27th December 2016
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Quote:
Originally Posted by rocketmangb View Post
Hey sapper !
I assume if its a rubber part its some type of seal even if just to keep dust out of the actual seal.
I'm sure the 04-05 seal is different from the '06 but I am guessing if you had a late production '05 it could have the '06 cover which is different.
Cool I will pick up a '06 seal and an '05 seal from J&P. I looked a little more into it and the '03 seal has the brass/metal ring that you are able to see from the outside. So right now my bike has an '03 seal. The '05 and '06 seals just look like a rubber ring from the outside. Thanks for the help. Hopefully this works.
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Old 27th December 2016
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Quote:
Originally Posted by sapper3858 View Post
Cool I will pick up a '06 seal and an '05 seal from J&P. I looked a little more into it and the '03 seal has the brass/metal ring that you are able to see from the outside. So right now my bike has an '03 seal. The '05 and '06 seals just look like a rubber ring from the outside. Thanks for the help. Hopefully this works.
The only other thought would be to lightly push it in to seat it.

I doubt the shaft is worn. However has it been dropped on the left side and possibly bent the shaft?
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