Why won't the clutch pushrod seal stay in?

montechoate

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New seal? That didn't help.
Silicone gasket maker? It held for a couple days.
Another new seal? Popped right out as soon as the engine started.
Same new seal, this time with a shitload of JB Weld! No, popped out as soon as the oil warmed up.

What am I doing wrong here?

I'm thinking about making a stabilizer out of hydraulic tubing to go over the rod between the outer case & the seal itself.
 
check clutch push rod isn't rusted causing it to drag out.

check that there isn't too much oil in the bike causing high crank pressure, ditto vent is not blocked
 
Cleaned the rod thoroughly & didn't even use the clutch last time before it popped out.
If the vent is the tube going from the case to the air filter housing, checked that already & it's fine, free flowing air.
Oil was at optimal levels.
 
Cleaned the rod thoroughly & didn't even use the clutch last time before it popped out.
If the vent is the tube going from the case to the air filter housing, checked that already & it's fine, free flowing air.
Oil was at optimal levels.

compression check the engine, worn bores could create excess back pressure
 
Is there an old seal in behind the new one? The new seal should be a tight fit and flush with the case. If the seal isn't inserted far enough, it will pop out.

And lube your chain better, it is rusting...
 
Drew: I was thinking about checking the compression anyway so that works out haha.

Dave: It's just the one seal, I can't get the fucker to fit flush either, I'm afraid I'll tear it up if I hit it any harder. Bigger hammer?
HA! I've used almost a whole can of spray lube in just a few months!
 
Are you POSITIVE that there isn't part of an old seal in there? Grab a bright light, a magnifying glass and some cleaner (e.g. aerosol brake cleaner) and have a good look.

No, the seal can't go in backwards.
 
Then the only thing I can think of is that you are either getting the wrong seal, or not installing it deep enough. It should be a very tight fit that requires a small (2oz) hammer to tap it in.
 
I used a deep well socket, But I also had a bur that kept ripping up my seals. The last time I put it in there, I was sanding the bur out, and the seal slipped right in. I used a silicon seal lube, to get it to slid in.
tobie

full
 
I've seen your post before, thanks bro. If I can't get it to stay in on it's own, imma tap the case & hold it in with screw & washers! :laugh:
 
Was there any solution to this? The pushrod seal on my bike also popped out. The new one popped out as well and leaked a ton of oil..

I replaced the pushrod too ao its all new stuff.
 
I know unless your taking the case apart, these seals seem to find spur, and then all you can do, is load it up with some case sealant, and hope it protects the damaged rubber portion, until you can get another one.
 
Went to have another look at the seal today. I took the rod out and made sure it didnt have any burrs on it and had a new seal ready..

When i pulled the seal out, i noticed some piece of metal caught around the mainshaft. I used a pick to get some of it out.

Put new seal in and went for a ride. 20 minutes later I heard a pop noise and the seal blew off again. I was very close to my house and got there. Oil was pouring out of the hole. I removed the pushrod and the popped seal and saw that the piece of metal that I tried removing, came out of place. I have no idea what the piece of metal is. It wasn't exposed at first like it could've been the metal backing from a previous seal.. It kind of just worked its way out into the seal area and pushed the seal out.

I was looking at diagrams before to try and trace the mystery piece down but theres really nothing it could be besides the metal backing. The thing that doesn't make sense is that was behind the case like it was a bearing shield..

I know the only real solution is to split the case here.. Im honestly getting fed up with the bike.

Im looking at XSR700s now..
 
New seal should have a metal backing. Best way to do any of these seals is to split the case.
 

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Went to have another look at the seal today. I took the rod out and made sure it didnt have any burrs on it and had a new seal ready..

When i pulled the seal out, i noticed some piece of metal caught around the mainshaft. I used a pick to get some of it out.

Put new seal in and went for a ride. 20 minutes later I heard a pop noise and the seal blew off again. I was very close to my house and got there. Oil was pouring out of the hole. I removed the pushrod and the popped seal and saw that the piece of metal that I tried removing, came out of place. I have no idea what the piece of metal is. It wasn't exposed at first like it could've been the metal backing from a previous seal.. It kind of just worked its way out into the seal area and pushed the seal out.

I was looking at diagrams before to try and trace the mystery piece down but theres really nothing it could be besides the metal backing. The thing that doesn't make sense is that was behind the case like it was a bearing shield..

I know the only real solution is to split the case here.. Im honestly getting fed up with the bike.

Im looking at XSR700s now..
hi did you ever get it fixed🤔
 
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