OK, just how screwed am I? (engine question)

[mac]

I was having a little oil leak from my clutch slave cylinder, so decided to put a little grease around the push rod (that goes over to the clutch) and the collar/spacer/washer thingy around the rod, keeping it centered in the hole. I pulled off the slave cylinder and pulled out the rod, but the collar around it stayed in place (last time I checked it the collar came out with the rod). Trying to pull the collar off it dropped inside…. Ugh! I could see it, and with one of those three pronged things that grabs little screws in computer components (push one end like a shot needle and 3 prongs come out the ohter end) I was able to put it in the hole and grab the collar. As I was trying to pull it out of the hole it fell back in, but this time dropped over the inside edge and down into the front gear case. I assume it’s right in front of where the Neutral Switch is connected there on the front gear case, just below where the slave cylender attaches.

There is no way to retrieve it now through that hole. For those who have taken the engines apart, is that area OK or is it in/on the gears, etc.? Is this one of those pull the engine things or can I get to it without such a major effort? (I guess it will be major either way) Anyway to just get that side off without pulling the engine? Am I totally screwed?

My heart sunk when that happened. I was trying to get the bike all in order for some nice riding this holiday weekend.

Sorry this is hard to describe, as it's not clear what I'm talking about from the service manual diagrams - I can't figure out exactly what part that is. But if I remember correclty, it may be a plastic or maybe metal part, about an inch high that goes in the hole that the rod comes through out of the front gear case.

If I had to pick it out, in the manual page 11-2 I believe it's the unnumberd part just below the "S-7" bolt and above the "ST-MO" nut.

On this page: http://fiche.worldofpowersports.com/...&B=23&Action=A
looks like oil seal part # 92049.

[cactusjack]

Okay...what part is this, exactly? The clutch pushrod seal that seats in the side of the case that prevents oil from leaking down the clutch pushrod?

[mac]

Yes sir, I believe so.

On this page:
http://fiche.worldofpowersports.com/...&B=23&Action=A
looks like oil seal part # 92049.

[cactusjack]

Yep, that's the pushrod seal. It isn't in the crankcase, it's down inside the bevel gear assembly. It probably won't do any damage. Just get a new one, clean the hole in the case real good and glue that baby in the hole with some gasket cement. Let it dry in place overnight and reinsert the clutch pushrod and mount the slave cylinder assembly.

Very common problem.

[mac]

Thank you, that's good to hear.

[Cajunrider]

You're not the first to lose one in the crankcase Mac.

[Top Cat]

So there is no danger of this getting into the gears and locking things up?
I'm really a Master Mechanic but just want to see if you guys actually know what your talking about.

[cactusjack]

Originally Posted by Top Cat (TC)

So there is no danger of this getting into the gears and locking things up?
I'm really a Master Mechanic but just want to see if you guys actually know what your talking about.

I don't think the seal is hard enough to cause damage. If there was an easier way to extricate it, then it would be best to remove.it.

[MAS Tequila]

There are NO gears for it to get caught in.

What is down there is the shift drum. It should fall past that and come to rest harmlessly at the bottom of the bevel gear drive case. The shift drum mechanism doesn't have the clearance for the seal to catch in.

If it really worries you it can be removed without pulling the engine.

BTDT got the t-shirt.

You would have to drop the swingarm, to get the driveshaft loose, then raise the back of the engine until it rests against the frame. It's tight removing the FBGD case, but I had to do it after a rebuild. The shift drum was off.

MT

[ponch]

If you can get it to the opening, can you grab it with a needle nose pliers?

[ccmjr77]

I had pretty much the same thing happen to me. Part of the seal if still in my case. I was told it would not hurt anything. Hopefully that is the case. No problems so far.
I ordered the part from CheapCycleParts for around $6, of course the shipping was almost $10.

[mac]

@Ponch: Tried, but couldn't - did use what looks like a metal shot needle where three wire prongs come out the other end to grab small things. Sorta worked, almost got it out the hole then it all slipped back in, but that time went over the edge and into the front gear case......

@ccmjr77: basically did the same thing when I ordered the part. Then I saw that Ron Ayers sells it for half the price and the shipping is half as well..... but the order was already in.

Thanks for everyone's feedback and support. I sure was hoping not to have to pull the engine just to get that part out. It's (good??) to know that others have had a similar issue with no adverse effects.

[mac]

OK - part came in and I installed it, replaced a couple of broken bolts (one holding my trunk rack, one on my left side cover), then cleaned up my starter switch (adding a little dielectric grease to help keep from corrosion) so all is good now and I'm ready to roll!

Thanks for all the feedback, it really helped me.

[BudMan]

Glad to here your rolling again.
I better bookmark this thread.