OK, my 1994 Hugger is weeping a bit of oil (tranny lube) from where the gearshift spline comes out from the left side cover. I'm guessing I need to replace the seal that I can see when looking at the spline going into the side cover. What is involved? I've not had the left side cover off before, but what the heck, I'm going to polish the side cover while I'm in there. Anyone else had this leak and fixed it? Advice?

Mine is leaking as well. I am going to try and do the change on the bike. It should be an interesting surgery.

}Get you a primary cover gasket set off Ebay.
}Be careful when removing/installing the clutch cable in the cover
}Make a sketch of the cover and bolt hole pattern on cardboard box. When you remove the bolts stick them in the same holes in the box.
}Clean the threaded holes good before putting it back together.
}Use a torque wrench.
The chain adjuster needs to be backed off before pulling the cover.

There is more, in the BOOK.

I would not pull the primary cover off to change the shift shaft seal. Pull the old seal out with a dent puller or a pick (drill a tiny hole in it first, then thread a screw into it to pop it out) then cover the splines with tape and grease and tap the new seal in with a suitable driver (i.e. deep well socket.)

You guys are doing way too much work if you're pulling the primary cover off to change the shift shaft seal.

--Chris

I had a leaking primary cover gasket and when reinstalling the cover I ruined the seal around the shift lever............

So it's best to just replace the seal, and if you're replacing the primary cover gasket, replace the seal after installing the primary cover.

Both my Sporties had weepy seals in this area and it never really bothered me till they actually started leaking badly.

I just did a quick fix on my 04 about a week ago.

All you need is an "O" ring that fits snug on the gear shift shaft. I have a small bag of replacement "O" rings for my tranny drain plug and this is the perfect size for the job.

Remove the gear lever and black rubber collar thingo.

Slide the "O" ring onto the shaft.

Replace black rubber collar and gear lever.

All fixed in less than 5 mins.

Zero leaks :)

This is the way several bike shops and myself do the repair in OZ.

I would not pull the primary cover off to change the shift shaft seal. Pull the old seal out with a dent puller or a pick (drill a tiny hole in it first, then thread a screw into it to pop it out) then cover the splines with tape and grease and tap the new seal in with a suitable driver (i.e. deep well socket.)

You guys are doing way too much work if you're pulling the primary cover off to change the shift shaft seal.

--Chris

All posts are very good advice. BT's are a PITA when the shifter seals start leaking. My high dollar Ultra was leaking before 25,000 miles. (38,000 miles now and no more leaks as of yet) My sporty just turned over 17,000 miles yesterday (82* and sunny in lower Michigan yesterday, just under 200 miles out cruising around with a couple of pals) and not a drop of anything has ever leaked.(knocking on wood as I type) I just checked the shifter seal and it looks cool. Other than a premature broken shoe lace my sportster hasn't let me down yet.

I wish I had read this first before doing the fix. I have a very strong pick that I was able to get under it to turn it out. It came out easily and then I used a boxend wrench with a small mallet to tap it in. I slipped once and scratched the chrome but I do that every time I work on my bike. I would do it the chrishhager way if I were to do this again. I bathed my fot in oil spray the other day and that was the last straw.

I would not pull the primary cover off to change the shift shaft seal. Pull the old seal out with a dent puller or a pick (drill a tiny hole in it first, then thread a screw into it to pop it out) then cover the splines with tape and grease and tap the new seal in with a suitable driver (i.e. deep well socket.)

You guys are doing way too much work if you're pulling the primary cover off to change the shift shaft seal.

--Chris

Just marking the shifter shaft seal post for future service reference in my posting list. Darn, that shaft belongs on the right side anyway! Whoops, just gave away my age!

The most important thing to point out is,it's a must to tape the shaft splines and grease the inside of the new seal before reassembling .Otherwise you will destroy the new seal right away.
Ralph

I had the same problem, kept changing seals every couple of months under warranty.It seems the seal like to pop out so a spacer in between the seal and the shifter peg is a good idea. I ended up changing my shifter shaft as it also wore out. Maybe you should check that if your Bike has been used alot .

Just an update on my shift shaft leak problem. I fixed it! I did what gronk62 recommended and used a tight-fitting o-ring (from a general purpose set purchased at local hardware store) on top of the shift shaft seal, along with a rubber washer just for good measure. These things along with the stock spacer force a tighter fit. The stock spacer now pushes on the rubber washer and the o-ring to keep pressure on the shift shaft seal and I have no more leaks! Thanks a bunch for the suggestions from everyone, especially gronk62!

Thanks a bunch for the suggestions from everyone, especially gronk62!

http://img.photobucket.com/albums/v341/gronk62/smileys/big.gif

Should that "black rubber collar thingy" (per Gronk) have space between the shifter and the seal, or should it be snug?

I've noticed that the bike shifts smoother and quieter if I place my toe under the outside of the shifter rather than under the middle. I can't detect any play in the shaft so I don't know if snugging up the rubber spacer would make any difference.

I have no leak at present.

Thanks.

Should that "black rubber collar thingy" (per Gronk) have space between the shifter and the seal, or should it be snug?.
It wasn't "snug" on either of my Sporties.

excellant to know the great ideas. I was going to fix mine tomorrow, The socket idea is perfect

My "black rubber spacer thingy" wasn't snug before my leak, but now with the o-ring and the very thin rubber washer installed it is snug. The snugness acts as a continuous force on the seal and I think that is helping prevent my leak.

Hi.
There is really no need for such an O-ring and rubber washer ,nor to be snug for the rubber collar.
Just tape the splines and grease the seal before installation.That´s the secret.
Ralph

Hi.
There is really no need for such an O-ring and rubber washer ,nor to be snug for the rubber collar.
Just tape the splines and grease the seal before installation.That´s the secret.
Ralph
The point of the suggestion about using an O ring was a quick simple 5 minute fix that works.