Clutch leak 748

[Calbuild]

Initial reason for signing up here is I am trying to find a qualified Ducati tech in or close to the area to assist with a current issue I have with some seals a and an oily clutch issue.  Running a ducabike slipper clutch. Trying to find an exploded view of the components and the sequence.

It works fine but I am getting a flow of oil out of the basket and drips down to my pipe and causes a nice cloud of embarrassment....
I have opened twice to explore source of leak
All seems to be in order

I did notice when clutch plates are out that the Clutch Housing that bolts to the Clutch/Crank gear move in and out about 3/16" / 3mm  Is it supposed too?
Spoke with a guy he said his does, it just seems like that much movement would have an effect on the oil seal.

While inspecting I run the bike with out the plates to see where the oil is coming from. Of course I get oil out the center of the clutch rod so I plug that up and get to operating temp, and I look for seepage. I see none.....
I suspect the Ring on the clutch side cover however it does not leak while test running. I also cannot operate the clutch with out the Rod installed...
I have the thought that when the clutch lever is pulled and the assembly moves out the 3/16/3mm that it will allow seepage..
I think I can put the the parts back in, less the plates and maybe get a visual of the drum & housing working and maybe be able to use the lever to see if I get any oil action.

Any thoughts?

[ducpainter]

I'd replace the pushrod seal and the large seal in the cover.

[Calbuild]

Hello Ducpainter

Thank you for responding

I have 2 fresh little blackies on the Rod

The Clutch cover ring is also new.....

Are you supposed to add a sealant or something to the Cover Ring Seal?

And the in/out play of the Clutch Gear is normal  ?

I had everything out and was looking at the next cover (covering gear)
I put a bolt back in on of the 8 holes and pulled on it....I find it to move back and forth a tiny bit....is this play normal  (was told yes, looking for confirmation)
It just seams it would leak from its seal at that point (reducing seal by almost 1/2)
Could be when all bolted down it doesnt move, but im thinking when clutch disengaged to the outside this part does move, but then why leak?....
anyways
I didnt do the original install and I made the mistake of letting one of my mechanically inclined buddies work on it last  
Maybe we can go over some basics and just make sure I have the right pieces in the right place..

First photo will be my pressure plate, the Rod, and a small plastic bushing and an Oring  these are correctly positioned i hope      yes /no  ?



Sorry about the dust....

Next photo is the end of the shaft the Rod goes into, I actually took a Mic to the shaft recess where these parts fit into and I say they are not deep enough?
So I added a second green oring to see what happens,  still has oil leak and no wear found on secondary oring??  hmm
I removed second oring prior to photo...still pondering.....


Thinking about another Oring...

now Im thinking its on the other side of next case cover....

is the shaft the Rod goes thru really supposed to have this much oil coming thru it?
Is it possible something else inside missing or broken?
Bike runs great, it did get thrown up in the air but everything externally has been replaced   motor working fine except this leak...
Which I cant really remember when started, I am almost certain it was when I asked my buddy do the clutch cause I was super busy.....
I'm on my third trip in....
Again I didnt see the original removal.....
New Orings every time   the big seal Im near certain is holding, no sign of leak while running stationary (I can see the edges, no seepage)

[ducpainter]

There should be a seal inside the shaft, just outboard of that needle bearing, in the lower pic... 93783.0812 Seal ring...not certain of the part# as I don't know what year/model 748 you have, but I doubt there's any difference.

[Calbuild]

Hi
Thank you for hanging with me


The seal you speak of....is it not the green Oring in the picture above?

The Green ring and that black spacer bushing both fit inside there...

Its a 99  standard issue  (no R)
I believe them all to be the same......

[ducpainter]

Hi
Thank you for hanging with me


The seal you speak of....is it not the green Oring in the picture above?

The Green ring and that black spacer bushing both fit inside there...

Its a 99  standard issue  (no R)
I believe them all to be the same......

I believe what you are calling a spacer is supposed to be a rubber seal and be captive in the shaft...shouldn't fall out by itself. The parts listing calls it a seal ring. The parts diagram shows the o-ring too. That shaft does have oil inside and needs to be sealed at both ends. I listed the part number above. You can look at the parts diagrams at ...

http://ducati.com/services/maintenance/index.do  The oldest is 2001. It can be saved or viewed.

I'd replace that black thing.

[Calbuild]

OK
Im going to chase the part number

the black thing is part of the Ducabike clutch im near positive   and its hard plastic not rubber....

I will try puting it in first and put the green rings following

I will follow on part, I will also try replacing plastic piece with a stack of Orings in the mean time...

I tried the link.....no parts available there for me, I even registered

Will run part number by dealer see if he can show me....

Would make a lot of sense if it was a tighter fit....

Thank you  

Found part on omaha fische
will get tomorrow!
that maybe the "Missing" piece,  or the replacement for this plastic thing....

I"ll try it!

Thanks for the new lead!

[Calbuild]

Allright

So I am still waiting for new little black thingy   but I did change the order and flipped the spacer/bushing over to a fresh side
and we have a 99% effective seal

No more Casey Jones


Thank you for your assistance Ducpainter

[Calbuild]

So the new seal came and I  installed per book
it leaks a bit more now....

I notice my set up does not have part 1 or 15   it says they are shims    I dont have on rod.....
When I had 2 greenies on  the outer side of black piece it was 99%
I am now putting one in front of plastic spacer, then spacer, then another greenie    see how that works
Hopefully the one on engine side will hold back the brunt of it

[ducpainter]

Parts 1 and 15 are inside the cases.

Can you tell if the seal to the bore in the shaft is leaking, or the seal to the pushrod?

[Calbuild]

Hello again

1 and 15 are inside?   I see that....thats good....I hope they are i there   lol

When you ask if its leaking from the crank bore or the pushrod seal I have to say I assume both and will inspect further

For sure I have seepage at the end seal to the pressure plate. I do have a drop there when I park

I also think it is getting out thru the bore somewhere as I often check the pressure plate from above at stop lights and nothing noticeable even if spinning.
Plus I think it would getting some on my pants   I really think its from just behind the pressure plate at the end of the shaft.

I have the basket out now and the end of shaft capped off  I want to make sure it isnt the case seal...so I am going to run it and observe

New question
I mentioned this thing and I were in a wreck, bike was airborne I dont know how far or high   lol

Is it possible there is a  exhaust valve or something stuck causing an increase in the oil pressure (all internal case pressure) that would be pushing oil beyond Oring spec??

this is about 12 times in and out with this clutch geez

I really dont want to throw a new assembly at it cause it works great, even with the oil.....has to be just a seal issue  or  internal pressure?

If I take it somewhere thats the first thing they will do I am sure, unless maybe I find a Ducabike rep/mech/tech.....

What do you think about the internal pressure thought?

[ducpainter]

I don't think it's internal case pressure. You'd probably see oil coming from the airbox also if that were the case.

I can't really tell. What I'd do is to run it with the pressure plate removed but the push rod installed. Clean the area well. Spray the area with aerosol foot powder and run it. You'll see exactly where the oil is coming from.