Shift Fork Oil Leak
Close
    
    
Page 1 of 2 12 LastLast
Results 1 to 10 of 13
Like Tree28Likes

Thread: Shift Fork Oil Leak

  1. #1
    Junior Member TW200Vermont's Avatar
    Join Date
    Aug 2015
    Posts
    3

    Shift Fork Oil Leak

    I have an older TW200, 1997 with both electric and kick start. Went down on the gear shifter fork and I have developed a small leak.
    How much surgery is it to get to the seal? I would like to do it myself.
    Thanks for any input
    Last edited by TW200Vermont; 08-02-2015 at 01:20 PM.
    jtomelliott49 likes this.

  2. #2
    Senior Member TW-Brian's Avatar
    Join Date
    Dec 2010
    Location
    Pleasanton, CA
    Posts
    5,720
    Welcome to the forum!

    To get to the shifter shaft seal you will need to remove the gear shift lever and the left (stator) side cover. This can be done without draining the oil by laying the bike over on its right side. Be careful about leaking gas and/or battery acid if you do it this way.

    Note how the wires from the side cover are routed and be careful not to pinch these wires when re-installing the side cover. You may also want to get a new gasket since you are likely to tear yours removing the side cover.
    littletommy and jtomelliott49 like this.

  3. #3
    Senior Member macbig2k1's Avatar
    Join Date
    Jul 2010
    Location
    Germany, Werdau
    Posts
    1,014
    For the side cover you can use the OEM gasket 3AW-15451-03-00 or from Athena S410485017041.
    I prefer the Athena gasket, much more cheaper and same quality.

    The part number for the oil seal is 93102-12106-00 (old number) or 93102-12321-00 (new number).
    But you can also find a fitting oil seal in a well sorted hardware store (or industry parts store).
    Here are the measurements: 12 x 22 x 5 mm (inner dia x outer dia. x hight)

  4. Remove Advertisements
    TW200Forum.com
    Advertisements
     

  5. #4
    Senior Member admiral's Avatar
    Join Date
    Jul 2010
    Location
    Frosty Hollow
    Posts
    13,046
    A little lookie loo with the stator cover and shifter removed.

    Hidden Content A ride in the woods helps me relax and release tension. The fact I'm dragging a body should be entirely irrelevant?

  6. #5
    Senior Member RockyTFS's Avatar
    Join Date
    Feb 2011
    Location
    Hailey, ID
    Posts
    3,338
    This is pretty easy and cheap to fix as above PROVIDED that you have not bent the shifter shaft. If it IS bent, any new seal will start leaking again soon. Pretty hard to do but not impossible. Once the case is off, put the lever back on while inspecting with a magnifying glass, you should be able to notice the shaft moving the seal around a little if it is bent.
    jtomelliott49 likes this.
    Rocky
    2018 TW200
    2014 BMW R1200GS LC

  7. #6
    Junior Member TW200Vermont's Avatar
    Join Date
    Aug 2015
    Posts
    3
    Quote Originally Posted by RockyTFS View Post
    This is pretty easy and cheap to fix as above PROVIDED that you have not bent the shifter shaft. If it IS bent, any new seal will start leaking again soon. Pretty hard to do but not impossible. Once the case is off, put the lever back on while inspecting with a magnifying glass, you should be able to notice the shaft moving the seal around a little if it is bent.
    Thanks all for the great info and support.
    Does the cover gasket go on dry or is there a recommended sealant?
    Is there a preferred parts supplier in the states that will ship parts?
    Athena seems to be European based.
    jtomelliott49 likes this.

  8. #7
    Super Moderator littletommy's Avatar
    Join Date
    Mar 2013
    Location
    Spokane, Washington
    Posts
    17,284
    Here is one place. Yamaha TW200 Parts and Performance - ProCycle#
    Some folks put sealant, some not. I use a little motor oil on the case side. So far, it's been off 3 times since and is still good with no tears or leaks. You can find the gasket cheaper elsewhere but these folks are pretty dependable.

    Warning: you may see other items you will want right away!!! Needed or not.
    jtomelliott49 likes this.
    1st John 1:9
    If we confess our sins, He is faithful and just to forgive us our sins, and to cleanse us from all unrighteousness.

    John 3:16
    For God so loved the world, that he gave his only begotten Son, that whosoever believeth in him should not perish, but have everlasting life.

    John 3:17
    For God sent not his Son into the world to condemn the world; but that the world through him might be saved.

    Hidden Content <<<Click here. Hidden Content

  9. #8
    Senior Member admiral's Avatar
    Join Date
    Jul 2010
    Location
    Frosty Hollow
    Posts
    13,046
    I order a lot from the site Littletommy posted and also from this site. Both are good. Most of the parts/items I order from Rocky Mountain ATV I get the next day, so good shipping speed. I try to bundle my orders to go over their free shipping cost when I can also, just so you know.

    https://www.rockymountainatvmc.com/?...campaign=names
    littletommy and jtomelliott49 like this.
    Hidden Content A ride in the woods helps me relax and release tension. The fact I'm dragging a body should be entirely irrelevant?

  10. #9
    Senior Member macbig2k1's Avatar
    Join Date
    Jul 2010
    Location
    Germany, Werdau
    Posts
    1,014
    I never use a sealant and I never had a problem with a oil leak.

  11. #10
    Senior Member admiral's Avatar
    Join Date
    Jul 2010
    Location
    Frosty Hollow
    Posts
    13,046
    Like macbig2k1, normally I do not use sealant either but have used the smallest dab of oil to help hold the gasket in place when putting the side cover back on. I did use a little RTV sealant when I put my side cover on a different engine. I was instructed to put it on extremely thin. This worked also, but again, this was mainly used to hold the gasket in place not to seal for oil leaks. (Thanks, evan & Fred).
    littletommy and jtomelliott49 like this.
    Hidden Content A ride in the woods helps me relax and release tension. The fact I'm dragging a body should be entirely irrelevant?

Page 1 of 2 12 LastLast

Sponosred Links

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  

Similar Threads

  1. Gear shift came off
    By billyedtimmy in forum General Discussion
    Replies: 5
    Last Post: 10-06-2014, 12:38 PM
  2. Tough to up shift!
    By Mkfchef in forum Technical Help
    Replies: 11
    Last Post: 09-23-2014, 06:46 PM
  3. Shift lever........???
    By Werloc in forum Performance and Customization
    Replies: 15
    Last Post: 08-29-2014, 09:05 PM
  4. Hot No SHift Fan?
    By Stromper in forum Performance and Customization
    Replies: 1
    Last Post: 03-17-2012, 12:57 PM
  5. shift problem
    By Thomas K in forum Technical Help
    Replies: 12
    Last Post: 01-07-2012, 03:30 PM