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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Replace Oil seal on Clutch "Push Lever" Assistance
Post Info TOPIC: Replace Oil seal on Clutch "Push Lever" Assistance
Rossyboys


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Replace Oil seal on Clutch "Push Lever" Assistance
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Hi All I have an oil seal that is leaking oil out and I have tracked it down to the Push Lever assembly seal.

Does any one have a step by set instruction or video on this .  I have the manual which touches on engine assembly (page 4-48) but doesn't go into just the seal replacement. 

ie first stage remove generator cover

then crankcase cover

after this is is it basically just the screw to remove  as the push rod retainer (as in picture attached with pen pointing at it), thus allowing  the push lever to come out then replace oil seal? could it be that easy??

 

Thanks 



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TTRfan


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I can't recollect ever having replaced that seal or ever having heard of one leaking confuse  Are you sure that is the source of your oil leak?

Yes - remove the screw and I reckon you can just pull out the shaft to swap out the seal.

What could possibly go wrong wink

Take more photos as you go please.

Brian



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Rossyboys


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Replace Oil seal on Clutch
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I cleaned the area yesterday took the bike for a ride and it seems to be the source. However I'll take it for another ride today, nice to get out to the shops for 10 on a bike. (take some pic and monitor the direction the flow comes from ) thanks for the feed back, yes I agree it is a most unlikely place

Cheers

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ttboof


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RE: Replace Oil seal on Clutch "Push Lever" Assistance
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I haven't tried it but a dusting of baby powder might help see where the oils common from



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Rossyboys


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Update Cleaned the area called (picture "Dry")

Then started bike 2 minutes and working clutch a few times and oil started to appearing up from seal (picture "oil")

Took short video (video"oil video") https://www.youtube.com/watch?v=i9H-hu4fbTs

Looks like a repair is needed to replace seal, anyone done similar work in this area, good to get some feedback pros and cons

 

 

Thanks Grahame



-- Edited by Rossyboys on Sunday 12th of April 2020 04:44:53 AM

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Rossyboys


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Short video uploaded , you will see the small pool of oil with the lever being worked backwards and forwards



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TTRfan


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Sorry Grahame but I can't see it - but I believe you that it's there - but why?

Is it possible your crankcase breather is blocked and the crankcase is over pressurising?

Is the breather tube clear and is there any oil in the emulsifier drain tube?

Brian



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ttboof


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Good call on a blocked breather defiantly worth checking out 



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Rossyboys


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No Blocked breather,

Hey found on another forum (Thumper) the Yamaha YZ450F had the same problem similar set up with push lever

thumpertalk.com/forums/topic/703409-oil-leaking-at-clutch-push-lever/

I might just be unlucky

will order some parts, not super critical at this point, just annoying.

Will post when done, to advise of problem

Thanks for the advice all

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Rossyboys


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RE: Replace Oil seal on Clutch "Push Lever" Assistance
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Just picked up new seal and and crankcase gasket in preparation any tips as I haven't done this before, always good to get any foresight on what I face, cheers



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ttr steve


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Sounds like we are all waiting for you to do it, pictures would be very much appreciated by us all.



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Rossyboys


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I have hit a snag need some advice please

I have removed the starter cover, crank case cover and removed the retaining screw for the push lever. The problem is that it the push lever won't come up and out . I have looked at the drawings and have concerns the clutch lever that en-gauges the clutch plates need to come out to allow free travel of the clutch push lever?? see pictures



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mossproof


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Looking at your last picture, there is a half-moon cutout which the push rod engages in. I thought it would have been a flat cutout but it is this that is stopping you from withdrawing the lever. You are right - need to remove the rhs engine cover and undo the clutch adjuster screw in the centre of the clutch basket, which will hopefully allow enough rightward movement in the rod to let it clear that half-moon.
There's a thread to show you the correct alignment of the clutch arm when you put it all back together:

ttr250.activeboard.com/t57238119/clutch-adjustment/

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Rossyboys


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RE: Replace Oil seal on Clutch "Push Lever" Assistance
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Completed the replacement of the oil seal on the push Lever assembly

Had to disengage the clutch lever on the handle bars then remove from the clutch cable from the push lever assembly and the spring

Then I had to remove the Starter motor cover, and the left hand sides crank case cover, The magneto coil holds it in place  so it just needs pulled away. Thus to expose the retaining screw on the lever. This was tight.

However the push lever assembly,could not be removed as the cross push lever 2  is engaged into the half moon cut out (see picture.)

 

Now the right hand side crank case had to be removed, firstly the kick start then rear brake springs and then foot peg.  Then the crank case cover could come off.  

I then removed the clutch (Plate pressure 1 part number ((11))

This then allowed enough play with the cover and plate removed to pull out the  "push Lever assembly"

Then a "circlip"  held down the oil seal . I removed the oil seal and could see damage to the lips of the seal allowing oil to ride up the shaft of the push lever.

 

I replaced both crank case gaskets with new ones and put back together.  

NO LEAKS  touch wood

.



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mossproof


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Result! Good work.
Thanks for adding the pics.
Hope you can get out and ride it now!

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