From reading the posts on this site and looking at my bike it I've narrowed down my leak to the Shift seal. I've been in contact with Cosmetic and I am ready to order the new seal.

I do have a service manual and will use that when I replace the seal.

My question is - my manual is at home and I'd like to order the parts from work today if possible - will I need to replace any other seals / gaskets as I pull the primary apart to get to the shift seal. I don't think I do, but will I need special tools to pull the inner primary of?

Thanks!

 

bump...

 

It can become one of those "While you`re in there" situations, you can replace every seal on the primary and tranny, or just replace what is leaking...

I would just replace what is leaking.

The other seals that could be changed are:

Starter jackshaft seal.

Primary seal (mainshaft).

Main drive gear seal and spacer.

Quad seal (under spacer).

Mainshaft/main drive gear seal.

You will need a 1-1/2" socket for the compensator nut and a big breaker bar. Clutch hub nut is 1-3/16".

A locking device to hold the primary drive while you untorque/torque the compensator nut and clutch hub nut. If your bike is a Dyna you should not use a wedge type locking device, otherwise you can use either wedge type or locking bar.

Remove the primary chain tensioner before you attempt to untorque the compensator nut or clutch hub nut.

Compensator nut is standard right hand thread.

Clutch hub nut is LEFT HAND THREAD.

Once you have the clutch off, clean the splines of the mainshaft and wrap some scotch tape around the splines, to help prevent damage to the seal on the primary case as you remove/install it.

Look it over carefully while you are in there, check the splines on the shifter shaft and shift arm. Before you remove the shifter arm from the shifter shaft on the tranny, remember you want to re install it in the same position (I learned this the hard way, no reason for you to learn it the hard way too..) Use a new snap ring on the shifter shaft.

New O ring between the engine case and inner primary cover.

As long as the gasket for the outer primary cover looks good, you can probably get by with using it over, they`re expensive, worth a try.

 

Thanks so much for the information.. Once my new seal comes in from Cosmetic I'll post how it went.

 

Glad you got the double lip seal from Cometic, much better than the HD one. Can be a PITA to get it out. If you can't get it out, you can fab up a little puller to do the trick.

 

I'm getting ready to do this project myself on my 05 Dyna....where were you able to find individual cometic shaft seals? There website only lists 5 packs, cheap enough but I only need one.

 

part number # OS041