79 R65: leak from Neutral Switch

[67siia]

I noticed a few drops of oil on the ground the other day. I cleaned the engine and found out where the leaks is. It turns out to be the neutral switch under the gearbox housing.

Anyone know any "I should know" before replacing it? At the same time I looked in the Haynes manual and it does not tell me the torque spec.

The search for one neutral switch and sealing washer begins.

Lastly, will all the gearbox oil drain from that hole? Should I draining it using the oil drain plug?

[67siia]

that's quick, BeemerShop has it:

P/N 6131097 - Siebenrock Brass Neutral Switch, 5-speed gearbox R2V Airhead 76-On @ $26.00
Washer @ $0.77  

[montmil]

Getting to that leaky neutral switch takes way more time than replacing the old with new. :-/

The rear motor mount bolt and the large aluminum tube-spacer must be removed. Other bits come away with that long bolt, too. With the bike on centerstand, devise a support under the engine to prevent any drop when the bolt is removed.

Drain the oil first as that slimy gearbox oil will prove to be a PITA cleaning off the shop floor.

Use caution removing the two wire leads. No worries about the bad switch but those spade terminals are far older than your girlfriend. An open-end wrench is the tool for removal as a socket won't work due to the male terminals sticking out. New crush washer, of course, and tighten to the guttentight specification. No heavy gorilla torque! Firm is fine. Don't forget to replace the wires!

Getting the tube spacer back in place is a minor challenge. Some folks will advise freezing the tube to "shrink" it. Fergetit. Summer in SoCal and that tube will be back to ambient temps in a New York Minute. Bevel the sharp edges just a bit and encourage the tube homeward with a small rubber mallet.

I do like to repop brass switches in my Airheads. No leaks.

[mrclubike]

Good choice!
 Most people have had  better luck with the brass after market ones over the aluminum OEM ones.
Some people cap  the new one  with JB weld (epoxy) just to make sure it doesn't leak.
Cap meaning the over the plastic part around the terminals not on the threads.
I personally would not mess with doing that to a brass one.

If you are close to a spline service I would just pull the tranny and do that and  all the seal and the switch at the same time.

[67siia]

brilliant, thank for the advises.... I will post an update when compete.

[montmil]

...Some people cap  the new one with JB weld (epoxy) just to make sure it doesn't leak.

Love me some J-B Weld but unsure if it would actually stick to the nylon surface of the new-style Neutral Switch. My Italian-made brass repop switch from Mootobins has been flying for several years now without issue.

If it ain't broke, we can fix that!  

[quixotic]

Love me some J-B Weld but unsure if it would actually stick to the nylon surface of the new-style Neutral Switch.

I sanded and rough-filed the nylon surfaces on the new switch I had to install a year or two ago (before putting some kind of heat resistant epoxy on it) and haven't had any problems since.

[67siia]

found on another site, good info including JB weld discussion:

http://www.advrider.com/forums/showthread.php?t=465741

[Ed Miller]

I got rid of mine.  I think I replaced it with a tranny drain plug and crush washer.  I maybe had to shorten the drain plug, I can't remember.  

[montmil]

I got rid of mine.  I think I replaced it with a tranny drain plug and crush washer.  I maybe had to shorten the drain plug, I can't remember.  

I'm with you, Cousin. One of my Airheads has the "Neutral Switch Delete" option. Don't miss it at all.

[67siia]

Disappointed with my purchase at Ted Porter’s BeemerShoo.  When I placed the order on the 25th of June, it did not indicate it was on back order. I waited and waited, sent an email requesting status and no reply. I called on the 6th of July and I was told these have been on back order for a while and they did not have an ETA; I wish they would have notified me.  Anyway, I looked on eBay and found one.  I canceled my order with Ted Porter’s BeemerShop and received the one from eBay in two days…sure I paid $4 more but worth every penny to have the Pig running. http://www.ebay.com/itm/300918854778?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
The neutral switch is replaced.  Was it easy? No way… should it be left to the professional? No way… take your time and it is accomplishable… Heck I did it.
1.      Following advice I cover the problem area of the new switch with JB weld.  
2.      Drained the gear box
3.      I supported the gear box with a jack & stand
4.      Remove the rear left & right side motor mount nuts and the long bolt.
5.      The removal of the aluminum tube-spacer was a bit complicated.  I sprayed WD40 the night before hopping this would help the removal… it did not.  I had to carefully hammer it until it came loose.  Once this spacer was out the rest is a piece of cake.  
6.      Removed the old switch, and replace it with the new one.  Note: I tested the new switch to find out which wire goes to which connection before installing it.
7.      Filled up the gear box.
8.      Here is the not so easy part.  The aluminum tube-spacer would not go back in.  I used my dremel tool to remove a bit from each side… then I placed the tube in the freezer for a couple of hours.  It went back it OK, I had to lightly tap it but much easier than expected. I pit some grease on the long motor mount bolt.
9.      Tested the Pig and all seems in good order.  I guess I have to give it a few days to see if it leaks again.
I am very grateful to all for the advice.

[montmil]

Now that the job is done, one of those long, bent tip, screwdriver-looking tools from Harbor Freight makes removal and adjustment of the tube spacer just a tab bit easier. That and a few well-placed strokes with a plastic mallet. Beveled edges help a bunch but I've never had luck freezing the spacer as I usually wait until it's 100+ in the shop to do stuff like this. Ambient air warms the spacer and leaves it nice n' wet. grrr...

You did well, Grasshopper.  [smiley=beerchug.gif]