I'm going to step into the "way back" machine here for a moment and refer back to your fork issues. We recently went through the forks on my buddy's '80 Special II and guess what we found? Yep, a "crunched" fork lower like yours. Even though he cleaned it up and polished it, you could still make out some "bite" marks on the lower where some idiot P.O. clamped it hard in a vice. It wouldn't slide all the way up on the tube, only about 2/3 to 3/4 of the way.

Ha! Yeah that was a real head scratcher for me for a while. I couldn’t figure it out, the fork tubes would slide in and get stuck before going all the way. If you remember, I had one lower leg that had a broken fender mount boss. After exploring all options I wound up buying and entire set of XS2 forks on eBay. I was kinda pissed that I had to buy so much to get one little part, but I wound up using both lowers, plus a bunch of internal parts that were either missing or damaged. It turned out to be a good buy! :D
 
Watching with bated breath. I too have a small oil leak at the counter shaft sprocket. Hope this seals things up.

Yeah, thanks, I’ll get back to you when I’ve had the chance to ride it again. Maybe I’ll sneak out in the morning before it gets too crazy hot.
 
So it looks like a new seal. Hmmm. I hope you get it figured out because I’m probably in the same boat.
 
So it looks like a new seal. Hmmm. I hope you get it figured out because I’m probably in the same boat.

Yeah it’s hard to say. I had another XS2 owner tell me that he did nothing special to his and he doesn’t have a leak.
I can live with a little seepage, I just don’t want to sling oil all over the place.
 
Copy that. That gold K1 of mine has a slight leak in the same place. It doesn’t get everywhere but I do need to keep a rag under the seat and wipe it off before it drips wherever I go. And sometimes it still will put a spot on the ground. Bummer.
 
... if I tried the grease, I wasn’t sure what kind of grease to use. I know I have greased other things before in these motors and the grease I used didn’t blend in with the oil and it wound up clumping on my oil filter screen...

Thick wheel bearing grease will work. Something that doesn't become like water when hot. It'll just set in the spline grooves, not go anywhere, and will just plug the oil's escape path...
 
Oil leak repair Part 2 .....follow up report.

This morning I took my bike out for a hard run, about 35 miles with a 10 mile long stretch of 60 mph sustained speeds. I got it good and hot and right after I pulled in the garage, I started to look things over. The first thing I noticed was that there was no oil on the rear wheel. Which there always was before. I felt encouraged.
I laid on the floor and looked up underneath the motor and saw......oil running down. Damn!

So I pulled off the cover to take a better look. I could see a line of fresh oil slung inside the cases and running down.
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Well this is just getting embarrassing now. But in the name of science and / or your amusement, I shall continue to experiment with theoretical solutions. I pulled the gear and spacer off.....again, and this time I noticed that the seal that had been formed between the spacer and the gear ( Yamabond ) had separated completely. I also noticed that the thin smear of Hylomar that I had placed between the spacer and the inner race, has seemingly dissolved and is missing in action.

When I tried the Hylomar, I was actually remembering something incorrectly. That was Jim’s suggestion to use RTV , not Hylomar. Perhaps the outcome would’ve been different. I still might go the RTV route. But first I wanted to try something simple and harmless and easily reversible if it does not work.

That is 2M’s suggestion of packing the splines with grease. Which is what I tried today. I packed the splines full of High temperature High pressure wheel bearing grease. In these locations,
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I also filled the space between the two lips of the seal with grease. This could work. The grease is essentially trapped inside that spacer between the inner race and the sprocket. I then reassembled everything and it’s ready for the next test ride.
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I need to order a couple of those lock washers. The one I’ve got is well used.

So...will this work? Your guess is as good as mine.

“ I know I’m not a smart man , but I am nothing , if not persistent. My mamma always said I hung in there like a hair on a biscuit.”
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To be continued......
Bob
 
So...will this work? Your guess is as good as mine.
If the grease still does not seal the leak , Perhaps try this Lol !
It does lose its lubricating quality fast but seems to stick real well
:laughing:
 

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It does lose its lubricating quality fast but seems to stick real well
:laughing:
Sounds like he's talking from experience. Astroglide to the rescue. Guaranteed to seal it shut..um, sprocket leak, that is. Who'd a thunk. Coconut to boot. Beats the smell of axle grease lol.
 
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