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Discussion Starter #1
A week ago I noticed a change in the grip pressure with the clutch on my 2004 K12RS. I checked the clutch fluid level and found it a bit low. I got the bike home without incident and it has been parked since then. I went through the effort to get to the slave cylinder (oh, how I miss some of my other bikes). The slave cylinder was wet and so was the cavity in the gearbox housing. I pulled out the pushrod and it had just a little bit of fluid on it. I cleaned everything up and ordered a new slave cylinder, gasket, and banjo bolt washers. While waiting for the parts to arrive, I changed the engine oil and cleaned up the bottom of the engine, etc. I checked in the slave cylinder cavity last night and I found a small amount of fluid. I shoved a paper towel in the cavity to dry things up. I checked again tonight and found a small amount of fluid again.

I didn't lose a lot of brake fluid, maybe about an ounce, so I am not too worried about the clutch being contaminated. I wasn't experiencing any performance issues with the clutch. I am concerned that the input shaft sealing ring (I think that's what it's called) may be compromised and is leaking fluid from the gearbox. Is this possible? The bike is on it's centerstand and would the gearbox fluid even be as high as the sealing ring is positioned on the gearbox?

If it is recommended to replace this sealing ring, is there a good procedure, outside of the what is in the service manual, for doing so? I don't want to purchase BMW's outrageously priced tools. Any suggestions or comments would be greatly welcomed.
 

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Yep, very possible. If you're in there, you might as well replace the engine rear main and tranny input shaft seals. Lotsa history on this failure mode, and the clutch pushrod was supposedly redesigned with a special wiper on it. You might want to look into that and make sure you get the new wiper. But the engine main and tranny input are also suspect.

Do a search, several folks have posted their R&R experience on this repair.
 

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Discussion Starter #3
I had read on another forum that the pushrod "clicked" into place on the clutch side. There is nothing on the clutch side to click into place. There is a detent on the slave side.

I don't have any leaks right now and I didn't really have a hard time getting everything apart. So, I may just wait for that leak to occur and deal with it then. I will check with the dealer tomorrow to see if they have the sealing ring and a new felt ring as well. Yes, the pushrod on an '04 has a felt ring on it. It is probably there to catch a little bit of fluid from a leaking slave cylinder.

Any thoughts on getting the sealing ring out without BMW tools???
 

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Discussion Starter #4
Okay. I got the new seal from the dealer today. I took a VERY sharp awl and knocked a hole into the seal material. Inserted a LONG, fine thread drywall screw into the seal. I used the frame of the bike as a leverage point and I finally got the old seal out. To put the new one in, I was able to use a 3/4" socket as a tool to set the seal in place. I think I got it in a little further than the original. Everything looks good and now I am still waiting for the new slave cylinder to arrive. It was supposed to come via UPS today, but it never showed up.
 
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