Gear oil leak

[beermak]

Hi. Ive found my brothers like is leaking gear oil. I cleaned everything 2 weeks ago and hoped it was just dirty but clutch is sliping again so i suspect the seal is gone.

I manage myself to do everything in order to take the clutch and have the shaft exposed.
As from there.. how should i keep goingo in order to replace the damaged seal and solve the leak.

Thanks!!!

[vespbretta]

If its just the seal behind the clutch you might be relatively lucky. Because from what I understand, this seal can be exchanged from outside, without taking apart the whole gearbox. So just pull the old seal out and press the new seal evenly in. Shaft, new seal must be oiled/greased in advance with proper oil/grease. Otherwise you will have to start over again.

But you might take something else into consideration:

How are the bearings? Are they in good condition? Is the shaft tight? Or does it have unwanted free play?

What Gear Oil do you use? And how much?
Don´t use  H Y P O I D  Gear Oil. This might harm/ruin your Kymco seals. Don´t know whether its just a rumor or not...but you won´t need the  H y p o i d  Gear Oil anyway for your little Scooter.
Use the correct amount of oil. 181ml. Not more. Use for example a 60ml syringe three times for the filling. Do not fill up to the fill hole until it drains out there. Filling up to the edge might/will cause blown seals.

I use Motul Gear 300 SAE 75W90 Full Synthetic. And I change it every year or at least every 5.000km.

[beermak]

Thanks for the reply. I recently disasemble the clutch to clean it and i saw a minor but crucial leak. Re sealed the seal with some silicon grease in order to give some time to get the new seal and replace it. But this lasted 3 weeks and the clutch is again oily.
Im using motyl gear 75w90 through 20ml syringes. It was the first change.. scoot had 5000km and had the original sae 90 inside i guess. (Had 3 dealer inspections 1000 3000 and 5000km).
Im gonna call to c if i can get the seal. Yesterday i saw some utube and seems a straight foward job.
Hope to find the spare and some time to do it.

Ps. The funny thing is that 2 months ago just before the warranty expire my brother got it fixed and lasted just a couple of weeks. Im suspecting they just cleaned and didnt replace anything. Now its over so we have to pay..

[Stig / Major Tom]

Thanks for the reply. I recently disasemble the clutch to clean it and i saw a minor but crucial leak. Re sealed the seal with some silicon grease in order to give some time to get the new seal and replace it. But this lasted 3 weeks and the clutch is again oily.
Im using motyl gear 75w90 through 20ml syringes. It was the first change.. scoot had 5000km and had the original sae 90 inside i guess. (Had 3 dealer inspections 1000 3000 and 5000km).
Im gonna call to c if i can get the seal. Yesterday i saw some utube and seems a straight foward job.
Hope to find the spare and some time to do it.

Ps. The funny thing is that 2 months ago just before the warranty expire my brother got it fixed and lasted just a couple of weeks. Im suspecting they just cleaned and didnt replace anything. Now its over so we have to pay..

Hold the Monkey here!
If they replaced that leaking seal....and it came back, warranty or no warranty...I sure would be having a chat with the service manager.
If that doesn't get you anywhere, I'd shoot KymcoUSA an email.
You have nothing to lose by conacting KYMCO, ask to speak with a service rep. and explain your situation. I found KYMCO USA to be pretty responsive to repairs if you present a reasonable case.
Stig

[beermak]

Hey stig im in argentina... the ppl that give service and handles the warranty are totally useless. 110%.... is argentina in the states this wont happen. Here they just dont give a... you need to take care of your things or nobody will.

For example i could claim it again. I shouldnt use it.. it will take me 5 to 6 weeks to get the bike into the shop. Meanwill no scooter and when they get it they are going to come up with something and not only ill be paying the repair they are going to invent the flux capacitor cant reach 1.2gw and doc brown will tell me that they are charging half a scoot in repairs.

[Stig / Major Tom]

Hey stig im in argentina... the ppl that give service and handles the warranty are totally useless. 110%.... is argentina in the states this wont happen. Here they just dont give a... you need to take care of your things or nobody will.

For example i could claim it again. I shouldnt use it.. it will take me 5 to 6 weeks to get the bike into the shop. Meanwill no scooter and when they get it they are going to come up with something and not only ill be paying the repair they are going to invent the flux capacitor cant reach 1.2gw and doc brown will tell me that they are charging half a scoot in repairs.

Well, that's poop!
Here's wishing you blue skies with your LIKE's seal!
Good luck, keep us posted please.
Stig

[beermak]

Will do! My father in law gets from the states on monday with some spares. after that will disasemble both transmissions to put a set of sliders (might be the first set of dr pulleys in argentina) and on my bothers change the seal leaking as well.
Ive been very enthousiast on sliders and finally get the chance of trying them.

[TroutBum]

Your situation sucks. I had a seal go, but fortunately for me it was under warranty and it has run perfect ever since. I hope you get things sorted out on the seal. Maybe contact Kymco for a free seal replacement. Can't hurt to ask.

[beermak]

Im opening the cover today so we'll se what happens...ive got the seal and will put some rollers also. Lets hope to see improvements

[beermak]

Good news... And bad! Fixed the leak, cleaned changed the seal put some new sliders.
Bike ran for an hour amazing... Until it started vibrating on take off. Previous it did the same and discovered the leak. Now im back to the begining but at least without a leak. Darn


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[vespbretta]

I also changed my kymco rolls to dr. pulleys sliding rolls (13g) today and sliding pieces. And I also cleanded the clutch and bell.
The sliding rolls performance is extremly smooth and remarkably improved compared to the original ones.
But I now also have some temporary vibrations on take off. But only when taking off very slowly and gently with a minimum amout of throttle (snail take off). It´s a Kymco clutch issue I guess. When I open the throttle a little more and quicker on take off, I don´t have the vibrations, because the clutch then locks faster.

Just adapt your driving style on take off. You will get used to it. And by the way it´s more fun, because you might leave some other riders and drivers behind you. 
Or buy a HIT Clutch.

[beermak]

Well.. i did my brothers and mine.m both with dr pulleys. My bike runs incredible. It accelerates waaaay muxh better and top end speed got close to 70mph flat (speedo).
I get a small vibration on soft takes off.. im aware but my brothers is the problem.
Did that vibration. Cleaned everything and worked flawlessly.. then again. Had a leak so we thought the clutch got dirty again and cleaned in this oportunity had the new sliders.. got them used the scoot for 45mins and back to the start. Vibrates a lot during take offs. Im done here.. its going to the shop.

[beermak]

How free should the variator back plate should spin in the shaft? If its kinda rough that might be my problem???

I suspect that cold it was ok. Thats my explanation why it worked fine and after some riding it started again vibrating. then it heats up and locks. And once its locked it doesnt mattet hot or cold.. that  thing is stuck again.

[vespbretta]

The variator backplate of course  m u s t  have some good clearance/slackness within the movable face of the drive pulley. It should not be stucked at all. Use a file on the gliding pieces to make your backplate work properly with some clearance. Are you using the correct sliding pieces? SP1814-H
With the Dr. Pulley sliding pieces, I got quiet a bit more clearance/slackness here. Approx. 1mm or even more. When installing the sliding pieces and testing the slackness of the backplate I first thought that this might cause some rattling, clacking  noises later on, but it didn´t. Operates smoothly and quietly.

Another problem with stucked backplates is that the dr. pulley sliding rolls can flip inside and cause malfunctions and vibrations. So make sure your backplate can move freely.

AND smooth the edges of the backplate for the dps with a file or a dremel tool! Very important step also.

[beermak]

Oh.. the backplate slides perfectlly smooth through the variator. Slides are fine and cleaned them. The clearence issue is within the backplate and the shaft.
Thats not moving freely within the shaft. That was the issue...