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Date Posted: Sat February 05, 2011 7:50:33PM
Author: Barry WA State
Subject: Re: Hey Barry: How hard is that to do?
In reply to: Scott Borderud 's message, "Hey Barry: How hard is that to do?" on Fri February 04, 2011 11:09:41AM

Very easy after you remove the polished aluminum cover. I wrote an article that was printed in the AVA voice. I forgot to mention there are just 3 bolts holding the slave cylinder to the motor. In case you aren't a member, here's a reprint:
THE PUSH ROD SEAL
This year while on the way back from the NW Regional Rally our Voyager developed an oil leak. Since this happened on the last day, we just kept an eye on the oil level & made it home safely. Once home, I was unable to determine where it was coming from. I cleaned everything up, let it run for ½ hour at 2,000 rpm and found no leak. I wrote it off as just being overfilled (for the first time in 11 years of Voyager ownership).
A week later I headed off on the CVV men’s ride. I immediately discovered that the oil leak was not fixed. Somehow in the back of my mind I was expecting that this would be a problem. I managed to ride 3 days and not have to add any oil, but the lower left side of the bike was a mess. No sooner than we got home, I got a phone call from Carroll Kelly telling me to go look at the AVA forum. It seems someone else had experienced the same problem from over filling. Carl Leo told them that the clutch rod shaft seal was blown out and just needed to be pushed back into the case.

A few days later, I removed the clutch slave cylinder and sure enough, the seal was just hanging there on the clutch rod. It seemed simple enough to push it back into place. I selected a deep socket that was about the same diameter to push it in. Since the seal was well lubricated, it quickly went right into the motor! I mean almost out of sight, but still on the clutch rod shaft. Kawasaki didn’t think a lip was necessary inside the motor to keep stupid Americans from pushing the seal into the engine case. I called Carl for advice & to order the seal, but he didn’t have any on hand. He gave me the part number and let me know this part is used in many Kawasaki motors and that the local dealership should have them. As usual, he was correct.

If you should ever blow this seal: 1. remove it completely 2. Leave the clutch rod in the motor. 3. Clean all oil residue off the external side of the seal. 4. Clean the oil off the engine case. 5. Apply a thin coat of JB weld or your favorite silicone gasket material. 6. Carefully push the seal into the motor, being sure stop when the seal is flush with the external part of the case.

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