Clutch rod crankcase seal

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nb1914

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Hi All,

I have noticed a small oil leak from the clutch pushrod crankcase seal seal. Is this an easy part to replace and is there anywhere in the UK that i get hold of one.

Cheers
Andy
 
It's not the easiest seal to replace, but probably not the hardest either. It can be considered one of the "rites of passage" of 650 ownership. They pretty much all leak, lol. Do a forum search for it because there are some tricks and tips pertaining to it. It's also a good idea to replace the bushing behind the seal while the seal is out. The seal is still available from Yamaha and most of the aftermarket places carry it too. Yes, it's a big seller, lol.

http://www.boats.net/parts/detail/yamaha/Y-93102-08206-00.html
 
I'm getting ready to replace my own pushrod seal and bushing. While I'm at it, I'm switching to a single long pushrod as the stock 2pc set has more play, causing earlier wear to the new seal and bushing. That's the theory, at least. Reports do vary. You can find more info in my Stella refurb thread. Mailman has pictures of his recent very neat pushrod job in his 60th birthday thread.
 
Hi nb1914: you might try Yambits in the U.K. I have never dealt with them (I live in Canada) but they seem to carry a wide array of XS650 parts and have a good reputation from what I can tell.

Pete
 
Hi MaxPete,

just ordered x2 seals and one bush from Yambits, I've ordered quite a bit of stuff from them their stock is quite impressive.

DanielBlack i would be interested in how you get on with the seal replacement, i ordered 2 as i expect a fight
 
A few sources suggest drilling the original clutch push rod bush out but it is a heck of a lot easier and less risky just to prise it out with something sharp like a scribe or even the point of a flat wood drill bit.
The bushes are made with a split so that when you drive them in they have some spring in them to stay in place.
if you prise out one side of the bush into the centre then you can pull the old bush out with some thin nose pliers.
I did a vid some years back when I replaced mine.
 
Thanks Peanut,

I assume the bush can't move back i.e. is seated allowing you to hammer something in to grasp it and pull it out. One more question before get stuck into it is:-
I made the mistake of running the bike with the left side crankcase cover off………….result large pool of oil and the pushrod plus a ball bearing in the middle ( bright side i guess is proves good oil pressure ) immediately stopped the bike. Scratched head and came up with the only conclusion after re-inserting the pushrod on its own that without the ball bearing the rod does not reach the clutch mechanism on the side cover…………now popped ball bearing back in followed by the push rod, was this correct ? the ball bearing is still in the side plate clutch mechanism so i assume there is one each end of the pushrod hopefully .
 
nb1914, Yes, If you have the one piece push rod, one ball on each end. One is inside the worm mechanism mounted on the left side cover. The other between the rod and the short T shape rod that actually presses on the pressure plate.
On the two piece push rod set up there is a third ball between the two push rod halves.
I have a diagram of the one piece rod set up. It doesn't show the one ball in the worm mechanism, it was not shown as an extra part, the factory crimped them in.
The two piece rod just replaces the one piece rod with a two piece and an extra ball.
Leo
 

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peanut said:
thanks Pete. did you hear me throwing all my tools about in the background lol.... it was the last tool in the box as usual.:rolleyes:
Click to expand...

Yup - the only thing I didn't hear was all of the "expanded garage vocabulary" which usually accompanies such a search. :cussing:
 

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