Over the weekend I replaced my 93 1500 shifter shaft seal. I will have to do my 92 GW seal too. Anyway, I was in good spirits to do this task as I had read on this forum that it was doable but exhaust needed to come off on the left side. OK, out in the back yard on the grass. tip bike over onto right side so on crash bars ( friend help me with this) OK, good, bike leaned over, left side fully exposed, side engine cover off, prior to full lean I took all engine covers off and front lower cowling as I also was installing the engine wind-age plate and was going to scrub the bottom of the engine.
OK, I was able to get to the 10mm bolt that holds the shifter intermediate shaft off and pull up and WTF?? No clearance from shaft to frame! You kidding me?? Now I know the engine was out of this bike 20K ago and could it possibly be that the engine sat 1/8 th of a inch to the left upon re installing? Who knows? So, I am thinking possibly if I DO take the left side exhaust off it would make a difference? Looking...no, that won't help. OK, this has got to give...play, play. struggle..oppps, pops off!! You have to find the correct angle/pressure/ pull to get it to come off the shaft. I read the seal will just pop off..correct, not a pressure fit like most seal installs. Honda must have thought that the intermediate shaft will hold seal in place? Well, I do not like that so I pulled out old seal with a screw driver as it's lip was bulging out and put silicone on the outer edge of the newseal and a blob of grease in the center of the seal and (like someone said, it will push in with your fingers) pushed in place after cleaning area with brake clean. I just wanted to let all of you know that doing this job is not bad if you play long enough to get the shaft off and the exhaust does NOT need to come off. I think using the silicone around the new seal will prevent it from "walking" out and seal better. No exhaust off and I ground some of the metal off of the intermediate shaft so if there is a next time, and this time to reinstall, it was/is easier. ( Made thickness thinner) My other tip..I did a 1200 rear tire change and yes, took the rear drive out to service. Upon re assembly of the drive shaft to trans spline alignment,I just started bike in neutral and when bike is cold, the trans will spin slowly in neutral and apply pressure to rear drive forward and the slow spinning trans will line up with drive shaft! Easy, took 10 seconds to get aligned. Hope this info. helps some of you in the future.
No photos, sorry, but when you take the engine "tins" off and lay bike on it's right side, it is all there in front of you. Just take note as to where the intermediate shaft aligns on the shifter shaft for re assembly. Make sure there will be clearance in the up shift mode to the frame. I had to re adjust mine as I noticed it would hit the frame on a up shift so I re aligned a few splines down and got the same clearance as prior to removal. There IS a line up mark on the intermediate to the shift shaft( you move with your foot) a dot and a triangle line up. Hope this helps and check your seal, all 1500's I have has leak or weep. These two bikes the seal poped out until it ran against the intermediate shaft.