Unfortunately yes, the lower case needs to be seperated from the mid case just to pop out that stupid seal.:headshake

How bad is yours leaking? There's a "cheap fix" way of correcting or at least slowing the leak if your interested. This will only work if it's leaking from the actual rod hole and not the space between the seal and cases.

Remove the rod, clean and dry the seal and about a 1/4 inch into the hole with some brake clean on a rag and use a Q-tip to clean inside the hole.

After everything is nice and clean, apply some RTV (I use orange but any color will do) to a dry Q-tip and lightly spin it around the hole but don't go in more than a 1/4inch! When your done you should be able to see though the hole and the rtv should just be around the inner circumference of the hole not blocking it!.

Let dry overnight. In the morning, make sure none of it will be pushed into the case by reinserting the rod. Re-insert the push rod and put it all back together.

This has worked for me and is a nice alternative to try before spending hundreds of dollars in labor to replace a $4.00 seal.:thumbup:

 

Unfortunately for me my mechanic tried to pull the seal and then later found out that it comes out from the inside.... so we tried to rtv the damage, but that didn't work.... it made it WORSE :headshake

i was just hoping that it wasn't true that it had to come out that way... but i guess i was wrong and its gonna look like i am gonna have to bite the bullet on this one... :damn:

Thanks for the Info!!!

 

Your mechanic should pay for some of the repairs if he made it worse.

What dealer did the work? :lol:

 

It wasn't a dealer, it is a personally owned and operated business and the guy does good work... i was just rushing him....

How much do you think a repair like that would cost... cause when i asked him for an estimate he said probably around 500 :headscrat

 

OOOOO... I forgot to mention that the reason the oil was leaking was because the guy i bought the bike from had snapped the chain and when it snapped it cracked and bent the clutch push rod which also tore the seal... so when he went to replace the rod and seal thats when this all came up....

 

$500 isn't too bad, there's a lot of labor involved and the motor must be pulled from the bike.

You might be able to just loosen up all the case bolts and pry the cases apart slightly to remove the seal, it's only being held in there by about a 1/4in on both sides of the cases.

If you must remove the lower case, maybe think about having the trans gears undercut and have the gearshift stuff freshened up (springs, cam, etc.) while you're in there. Way cheaper while it's already apart for the rod seal then doing it later on.:hmmm:

good luck.