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Leak from countershaft plug on my 1135

J

John Kat

Forum Sage
I've just finished rebuilding a 1135 engine to fit into a GS 1000 E frame.
One issue however: there is an oil leak from the countershaft plug.
Has anyone tried to replace it with an aluminum plug fitted with a O-ring?
I've tried replacing the plug with a new OEM one but having to force fit it in it's location ruins the outer rubber band and the sealant didn't help.
I'm sure the racers out there must have a solution short of opening the bottom cases

IMG_P7.JPG
 
Last edited:
If you are going to install the plug without splitting the cases, you must chamfer the leading edge of the bore slightly. The sharp edge will always cut the new seal. Dar
 
I decided to have an aluminum plug machined to replace the OEM countershaft plug.
The diameter of the plug is currently at 46.95 mm.
It can be force fitted in the countershaft hole but it will be reduced by 10/100 mm to be able to remove it without too much pain.
The O-ring has a diameter of 1.75 mm.
This is what it looks like currently:
 
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