Countershaft Seal Leaking After Rebuild

Energy One
PHATASS

PHATASS

Active Member
I sent my transmission out for rebuild a few months back due to a worn main bearing at 18K miles and a cracked case caused by a hydraulic press malfunction. After getting the trans back with the new case, I’ve been having a problem with the left countershaft seal slowly leaking after short rides. Other than the leak, the transmission shifts flawlessly. I’ve had the transmission out 3 times double checking alignment, shimming, and any other factors that may cause the leak and can’t find anything wrong. I also noticed a vibration/shake throughout the bike only at higher rpms when engine braking and just before up-shifting in the lower gears but can eliminate the vibration/shake completely by pulling in the clutch handle. I’ve been through every component in the primary, transmission, torqued motor mounts and replaced the countershaft seal but still having the same issue with vibration and leak. The only other thing I can think of is an out-of-round condition where the countershaft bearing fits into the case. Any suggestions would be greatly appreciated.
 
RRRUFF

RRRUFF

Well-Known Member
Be sure the tranny vent is open. I had a problem with the starter jack shaft seal allowing primary oil to leak back into the starter motor. I replace the crankshaft seal oil leak is gone. I know this isn't much but unless the counter shaft has a defect where the seal runs, don't know what else it could be. The vibration is another issue. Check the run out on the shaft. Don't know what the tolerance is but if it seem excessive could be causing your vibration and leak issue. Hope you find the problem.
 
PHATASS

PHATASS

Active Member
Thanks for the reply. You would think the runout on the shaft would have been checked prior to assembly and any leaks would have been noticed during bench check so I hope that doesn't turn out to be the problem. Also didn't have any vibration problems prior to the rebuild.
 
RRRUFF

RRRUFF

Well-Known Member
Yeah, I think the vibration maybe the key here. Hope its nothing serious. Did you get a warranty with the rebuild?
 
PHATASS

PHATASS

Active Member
Member gave 1 year warranty on the bearings. However, it would cost me $140 dollars for two way shipping again just to get it too him not counting the time invested in previously pulling the transmission 3 times plus fluids and seals/gaskets etc. After I installed this newly rebuilt transmission in my bike, I took it for a short ride down the rode and it almost locked up on me. Got it back home, took off the top cover and all the bolts holding the pillow block were loose. Good thing i didn't make it to the on ramp of I-80 out here in Cali where the speed limit is 75 mph. If it would have locked up then, I probally wouldnt be typing this email. So I decided I didnt want this individual touching my transmission again and looked at it as a lesson learned. Figured if I get into a big enough bind, Mr. Andrew Barnes is just a phone call way! Wish I would have went through him in the first place, lol.
 
PHATASS

PHATASS

Active Member
Found The Culprit!!

Had the time this past week to once again tear into my transmission to finally get to the bottom of this leak. I had been on the road a lot over the past year at the governments expense:flag: and this allowed me time to gather all the required Baker tools to go ahead and just rebuild the transmission myself so I knew it would be done correctly. It didnt take long to find the culprit and after all the problems I had with the trans after I first received it back from the rebuilder as decribed above, it shouldnt have surprised me that the individual failed to install the damn shift pawl seal too:bang:. I would never have thought someone with any attention to detail would have missed this! I thought my countershaft was leaking since the fluid would pool to the bottom of the countershaft seal by the time I pulled the primary off to see it. Oh well, we live and we learn....:D
 
PHATASS

PHATASS

Active Member
Not sure chacha....I replaced the bearings and installed the upgraded hardened mainshaft and vibration went away.
 
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