Clutch Push Rod Gasket

[fakebikerdude59]

I had a curious mechanical issue last week on my 08 Nomad that I want pass along. I made my weekly 130 mile jaunt from Tacoma, WA to Bellingham, WA last Wednesday morning. When I got to Bellingham, I noticed an oil spot under the Nomad. This is the first time I have ever seen any oil leakage. I had just performed the 12K service two weeks ago, changing both the oil and the final drive oil. My immediate thought was a loose plug or seal. I checked and there was no oil residue around the oil plug or anywhere on the final drive assembly. It seemed the oil was leaking out of the transmission somewhere.

Not wanting to get stuck on the road, I called the local Kawa Dealer (Mt. Baker Motosports) and they were able to fit me in. It turned out the clutch push rod gasket was out of place. Seems like that is something very unusual. It was not damaged, so they put it back in right and everything seems to be fine. Rode home and no leaks. Also, my shifting is much smoother and has a shorter throw between gears, so I don't know if that's something that came from the factory that way and finally got bad enough to show up, or something that happened through riding.

Anyway, it was handled as a warranty repair, so I was very happy. Folks at Mt. Baker Motosports were very accomodating and easy to work with. And I drooled a bit over the 2010 Voyager on the showroom floor while waiting for them to finish.

[blowndodge]

Unfortunately that is "Not" unusual.... many of us here have had to re-seat that gasket and permatex it in place...

[cactusjack]

That isn't the least bit "unusual". Many of us have had the clutch pushrod seal come loose. Happened to me last year.

[fakebikerdude59]

Thanks for the info. The service desk told me it was unusual. Now that I know it's not, I can monitor it.

[cactusjack]

Originally Posted by fakebikerdude59

Thanks for the info. The service desk told me it was unusual. Now that I know it's not, I can monitor it.

If they fixed it correctly, it shouldn't happen again.

[Dave]

Had that happen to me on my 08 Nomad with on 1500 it. At least my HD got 2500 before any oil leak!

[Jared]

Where is the clutch pushrod gasket exactly. I've never had any problems up to this point, but I wouldn't mind learning a bit more on the subject in order to be prepared and unalarmed when it does happen.

[cactusjack]

Originally Posted by Utah Motorcyclist

Where is the clutch pushrod gasket exactly. I've never had any problems up to this point, but I wouldn't mind learning a bit more on the subject in order to be prepared and unalarmed when it does happen.

If you remove the left side cover, you'll see the clutch slave cylinder there. Behind that is a metal pushrod that goes from the slave cylinder through the crankcase to the clutch assembly on the right side. There is a small seal that fits in an opening in the LH side of the crankcase to prevent leakage around the pushrod. That seal works itself loose and provides a large hole for oil to leak through. It typically doesn't leak a lot of oil, but you'll find it dripping in the area of the sidestand pivot.

[Jared]

I searched but couldn't find a write up on this problem on the gadget page. Did I over look it or has nothing been written up on the subject?

[cactusjack]

Originally Posted by Utah Motorcyclist

I searched but couldn't find a write up on this problem on the gadget page. Did I over look it or has nothing been written up on the subject?

I don't know, but I can't get to Gadget's site from work to look.

It's an easy fix. You remove the left floorboard and shift levers and the left side cover. Remove the slave cylinder (3 bolts) and if the seal is loose, it will be sitting somewhere on the pushrod. Remove the seal, clean it good and clean the hole really well and use Permatex gasket adhesive on both surfaces. Put a little oil on the inside of the seal and slip it back over the pushrod into the hole it's supposed to sit in. DON'T PUSH IT ALL THE WAY INTO THE CRANKCASE! Once it's seated, let it sit overnight for the adhesive to cure. It's kind of like contact cement. Reassemble and go ride the bike.

[bkmaxvrb]

lol!!! I was going to add my 2 cents that this isn't an unusual problem what-so-ever. But, everyone beat me to it. I guess I shouldn't work 4 - 12 and expect to see new topics right away.

It happened to me and it was a quick and easy fix. Matter of fact, I got all the info I needed about diagnostics and how to fix it right here on this wonderful site from these wonderful people.