Hawk shifter seal installation

Dusman · 03-06-2022, 04:41 PM

I have a question about the best way to go about properly installing a Hawk 250 shifter seal. I watched several online videos, replaced the seal, and it leaked. I spoke with a friend of mine who is a motorcycle mechanic, and he said to use a thin coating of black RTV around the outer diameter of the seal before installing. He also noted to thoroughly clean out the shifter seal cavity with brake parts cleaner and make sure it was a clean, dry surface. I did all of that and it is still leaking around the outer diameter at the bottom of the seal, which indicates to me that I didn’t properly install it.

I’m open to any advice from those with experience successfully replacing these seals as to the best process you’ve found so that they don’t leak.

Thanks

severely · 03-06-2022, 05:32 PM

Quote:

Originally Posted by Dusman

I have a question about the best way to go about properly installing a Hawk 250 shifter seal. I watched several online videos, replaced the seal, and it leaked. I spoke with a friend of mine who is a motorcycle mechanic, and he said to use a thin coating of black RTV around the outer diameter of the seal before installing. He also noted to thoroughly clean out the shifter seal cavity with brake parts cleaner and make sure it was a clean, dry surface. I did all of that and it is still leaking around the outer diameter at the bottom of the seal, which indicates to me that I didn’t properly install it.

I’m open to any advice from those with experience successfully replacing these seals as to the best process you’ve found so that they don’t leak.

Thanks

A couple questions, if you don't mind. How are you installing said seal? Is the case damaged where the seal was removed? Are you tilting the bike slightly to the right side to keep oil away from the silicone around the seal so it can dry overnight before you go for a ride?

Dusman · 03-06-2022, 06:52 PM

1. Yes, case is slightly marred from the seal being removed where the screw I used to take the seal out nicked the case. The nick is more toward the outer edge of the case, but it still could create a valley for leakage.

2. I drained the bike completely of oil, then after removing the seal, did the clean up/drying job in order to have a dry mating surface. I did *not* tilt the bike to the right overnight after reinstalling the seal with the RTV sealant. I did allow it to dry/set up for 24 hours before re-adding fresh oil.

TominMO · 03-06-2022, 07:27 PM

Quote:

Originally Posted by Dusman

1. Yes, case is slightly marred from the seal being removed where the screw I used to take the seal out nicked the case. The nick is more toward the outer edge of the case, but it still could create a valley for leakage.

So you need to repair the case where the nick is. Perhaps a bit of JB Weld on your finger, to fill in the scratch, then wipe off any that is not in the scratch. Let it set up a day, then install a new seal.

If it is too hard to get your finger in there, you could use a pipe cleaner, Q-tip, etc.

TxTaoRider · 03-06-2022, 10:52 PM

Try cleaning up the burrs and get the area clean and dry of oil. Then apply a little Permatex "The Right Stuff" (black) around the outside of the seal then install the seal. Let it dry a few minutes and go have fun. That stuff is impervious to oil and thick enough to seal up imperfections.

Also check your vent hose for blockage, as that can cause the crankcase to build enough pressure to make oil leak from the seals.

Dusman · 03-07-2022, 09:12 AM

Thank you. Good idea on the vent hose. I did not think of that. I did use Permatex on the seal originally, but I will definitely check the vent hose.

Dusman · 03-07-2022, 09:14 AM

Thank you. The little nick in the case could literally be filled in with a little dab of JB Weld on it on the end of a toothpick. That is how small the nick is. I didn't think it would leak with that nick being so small, being at the outer edge of the case, and with also using RTV sealant. Obviously, I was wrong and any imperfections in the sealing surface can lead to this.

03-06-2022, 04:41 PM	#1
Dusman Join Date: Jan 2018 Location: NC Posts: 206	Hawk shifter seal installation I have a question about the best way to go about properly installing a Hawk 250 shifter seal. I watched several online videos, replaced the seal, and it leaked. I spoke with a friend of mine who is a motorcycle mechanic, and he said to use a thin coating of black RTV around the outer diameter of the seal before installing. He also noted to thoroughly clean out the shifter seal cavity with brake parts cleaner and make sure it was a clean, dry surface. I did all of that and it is still leaking around the outer diameter at the bottom of the seal, which indicates to me that I didn’t properly install it. I’m open to any advice from those with experience successfully replacing these seals as to the best process you’ve found so that they don’t leak. Thanks
	0

03-06-2022, 10:52 PM	#5
TxTaoRider Join Date: Oct 2020 Location: Flower Mound Texas Posts: 904	Try cleaning up the burrs and get the area clean and dry of oil. Then apply a little Permatex "The Right Stuff" (black) around the outside of the seal then install the seal. Let it dry a few minutes and go have fun. That stuff is impervious to oil and thick enough to seal up imperfections. Also check your vent hose for blockage, as that can cause the crankcase to build enough pressure to make oil leak from the seals. __________________ 2021 Tao Tbr7 - "Lucille" Mods so far- Brozz swingarm, 21" front rim (Bridgestone Tw302 rear/Dunlop D606 front tires), Digital gauge cluster, pz30b pumper carb, after market hand guards, aftermarket brake and clutch levers, round fold away mirrors, Fly handlebars shortened slightly, 13t front sprocket 2009 Q-link Legacy 250 1982 Suzuki GS1100ES - "Jolene"
	2

03-06-2022, 06:52 PM	#3
Dusman Join Date: Jan 2018 Location: NC Posts: 206	1. Yes, case is slightly marred from the seal being removed where the screw I used to take the seal out nicked the case. The nick is more toward the outer edge of the case, but it still could create a valley for leakage. 2. I drained the bike completely of oil, then after removing the seal, did the clean up/drying job in order to have a dry mating surface. I did not tilt the bike to the right overnight after reinstalling the seal with the RTV sealant. I did allow it to dry/set up for 24 hours before re-adding fresh oil.
	0

03-07-2022, 09:12 AM	#6
Dusman Join Date: Jan 2018 Location: NC Posts: 206	Thank you. Good idea on the vent hose. I did not think of that. I did use Permatex on the seal originally, but I will definitely check the vent hose.
	0

03-07-2022, 09:14 AM	#7
Dusman Join Date: Jan 2018 Location: NC Posts: 206	Thank you. The little nick in the case could literally be filled in with a little dab of JB Weld on it on the end of a toothpick. That is how small the nick is. I didn't think it would leak with that nick being so small, being at the outer edge of the case, and with also using RTV sealant. Obviously, I was wrong and any imperfections in the sealing surface can lead to this.
	0