Oil Leak

[gilburton]

Well seals leak for a reason! When you get the clutch off put a tube over the shaft and lever it up and down.You did mention it seems worse when you carry a passenger so this would suggest movement somewhere with the extra weight??
If the bearing is ok then the problem must lie with the seal even if you have fitted a new one it may have been damaged somehow?
When you fitted the seal you did tap it in gently using a large socket or tap gently all around the edge of the seal at different points?
Am I correct in assuming the spacer is just a steel tube and can be pushed over the shaft through the seal after you have fitted the seal? If so make sure there are no sharp edges on the spacer and use a bit of grease when pushing it through the seal.
If there is a round edge on the spacer this is the edge that goes through the seal.
I don't see any reason why the seal can't be fitted after you have removed the clutch so a new seal should sort it if the old one is damaged.
I notice you seem to be working outside so I understand as the weather is a bit cold. One thing we used to do on the old British bikes was remove the front sprocket at the same time as the clutch then the whole thing could be lifted away with the chain as well.
The only other option I can think of is that the oil is working it's way along the shaft inside the spacer/bush??
Is the spacer a good fit on the shaft?

[alexanderfoti]

I will give the leverage a go to see if there is any play there.

Its possible its damaged although I did check for nicks and scratches before I fitted it and it looked okay.

The distance piece is just a shim of metal and goes inside the seal and around the shaft, that looked like there were no sharp areas there.

I tapped the seal in using a large socket that fitted the seal, i didn't do it at different points.

I will have to have a look at the seal as it does look like its toast, which itself is a pain as its brand new! (well was)

removing everything isnt such an issue, its getting the clutch biting point etc back to what I have used to each time I remove the clutch

[gilburton]

When you say " just a shim of metal" What do you mean? Which part number in the diagram are you talking about?
You have fitted the bearing seal "9" inside the gearbox behind the bearing?

[alexanderfoti]

in this image:

http://villiers.info/images/pic/AXG324X.jpg

Part number 7

Part number 9 is just a shim of metal that I replaced when I replaced the bearing.

[gilburton]

I thought for a moment you had fitted the bearing seal on the wrong side when you said "shim" as this would have explained the oil leak.

[gilburton]

There is another solution but you won't like it. That is to strip the box down and fit a sealed bearing. That combined with the oil seal should make sure NOTHING comes out.
A new seal and bearing will be available locally if you take the parts or numbers to your local bearing supplier.

[alexanderfoti]

Yeah although if that was damaged would it cause it? I remember it had a dimple in it when I replaced it.

[alexanderfoti]

At the end of the day, if the sealed bearing sorts it then I wont really mind. I should be able to do it quickly as I have had the box apart a fair bit now :p

I should be able to find something from bearing boys, the bearing size is 25 X 52 X 15mm

[gilburton]

Well all I can say is part 9 is described as a "seal" not a shim so if it is not perfectly flat or concentric then it can't help.
I assume it does the same sort of thing as a sealed bearing although not as well.

[gilburton]

Get a seal from them as well. It'll be a standard size get the numbers from the old seal.
When you fit it you'll have to put part 9 back in as well as it will act as a shim/spacer or your shaft will move.
Now I said earlier the oil may be working it's way up the shaft,although from what you say the leak is too much for this. Have a look at part 4 "dished washer". This looks like a "crush" washer and may seal the shaft?? Ask villiers services why it's there and not an ordinary lock washer.

[alexanderfoti]

My thoughts as well, I will replace it when I get a chance I think

[gilburton]

We're crossing posts have a look at my last post re part number 4

[alexanderfoti]

Ah yes im thinking that its too much oil to leak out of the shaft, im thinking it must be leaking through the bearing and then the seal.

Ill give them a call tomorrow to see what can be done and what they suggest

[Rhynri]

Just here to wish you good luck with this issue, sounds like a real pain.

[alexanderfoti]

Thanks! Its a major pain in the arse, Im sure I must be missing something, although I think a sealed bearing will help a lot!

[XLerate]

Could it be that the selector shaft is excessively worn at the seal area such that the seal lip is no longer able to stop oil seepage? On some of the crankshaft front seals there's a repair part used to make up for wear on the shaft, a shim bushing of sorts that slips over crankshaft and inside seal. Possibly that's an option if you can find materials to correct any void or wear on selector shaft?

If not it may be possible [and a whole lot easier!] to simply cross reference the seal part number and dimensions specification, then locate another seal to correctly fit inner diameter of casting hole it's pressed into but made to fit a smaller shaft, to better seal the moving part of shaft? Just a few thousandths tighter would do nicely.

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