The Elusive Oil Leak Mystery - Resolved!!!

[DEcosse]

Originally Posted by Sparti

.... can you post pics of the exact area that was leaking ....

It's actually in the pics in the first post - that shaft end that is the lower right section with the retaining clip on, is the selector fork shaft.



There is an o-ring about 1/2" into the case.
You can actually withdraw the shaft far enough to replace the o-ring (being EXTREMELY careful not to pull it out TOO far!)
Similarly, when putting it back in, you have to be even more careful of pushing it in too far - see my note in the post above about holding the end of the shaft with vize grips so it doesn't 'get away from you'.

However, if you can successfully seal the bolt-hole you suspect is the problem, then it may well be that screw-hole - in my case the oil migrated to the hole slightly above the selector shaft, but not as far as the next hole up from where you think its originating for your situation.

This is actually a 97-01 Transmission Gear-Change Case - but essentially the same regarding the shift drum and selector forks on my 02-04 series engine and also the 1050 motor.
The upper shaft carrying the selector forks that is almost directly in the middle of the pic is the one that had the leaking o-ring seal (that would be the one effectively at the top of the pic, actually the left side of the case)
You can see that you would not want to pull the shaft out too far!




As a postscript, I tried replacing this o-ring seal several times, with no joy, the leak persisted.
It was definitely coming from the selector shaft seal and ultimately it was 'resolved' by using a sealant around the shaft, applied just prior to putting into final depth.

[1peter]

DEcosse, i have to know, what happened the 1st time you did this and pushed the shaft in too far ? What had to be done to remedy that ?

[DEcosse]

You can reach it on the other side so not completely the end of the World - but have to remove the clutch assembly - makes a small job into a significantly bigger job.

You can see the end of the shaft in this pic - it's at about 7 o'clock off from the input shaft
(Between the input shaft and gear selector star)

[1peter]

Well, i bet you don't do tha again eh ?

[gsmitty]

Hey DeCosse

I have a 2011 Sprint with the same mystery oil leak. And it would appear prior to removing the front sprocket, I can see oil film on the end of the Selector shaft.

I will let you know my result- thanks for the great post

[DEcosse]

With a 2011 Smitty, I would sincerely suggest you take it in under warranty.
You can certainly suggest that they attempt this fix with the method I used, but if it goes pear-shaped then they have the onus to strip it (which is what I believe the 'normal' Factory suggestion for replacement would be)
i.e. for them it is no-harm risk to attempt - if it goes wrong for you, you will be wearing the consequences yourself.

[gsmitty]

Hey DEcosse

Just out of warranty, purchased at end of 2010, but will see if Triumph will make an exception.

Doesn't seem to be a tough job as long as I follow your careful steps :-) . Dont want a dealer to work on and then up tearing the engine apart- which could then lead to other leaks.

Thanks for your help!

[DEcosse]

You can also try just cleaning real well with a solvent, then applying a sealant around the shaft, behind the keeper plate. I ended up doing this anyway.
Good Luck!