2.5 using oil

TURBO200R4 said:
DO NOT CARVE THIS IN STONE (SORry caps
i am thinking that maybe it only takes one and they sale them in 2 per package?
i would guess that you install the oring first and then the sensor so not to clip the oring.
Click to expand...
There were two on there that I removed and there are two shown in the diagram (above). There is the option to order just one., but two are listed as the number needed. So, that's the "design," but it's obviously is lacking. One that is wider and sits a little more proud would work better
 
Sounds like to me there's something wrong with the machining on your gear position sensor. If it was an inherent design flaw this problem would be showing up on more bikes. If the o rings have been replaced twice and the problem persists, there's something else wrong that's stopping them sealing.
 
The O-rings should be installed on the sensor prior to installation, then coated with P-80 or equivalent to reduce the risk of damage/movement during installation. Given that this issue has cropped up on several bikes, but only recurred on one (that I'm aware of), I'm willing to bet that it's an installation issue.
 
I've generally found that when replacing o rings and seals you're advised in the instructions (if you've got any) to apply a smear of whatever fluid it is they will be dealing with during use - ie. oil on engine parts, fork oil for forks seals, brake fluid on calipers and master cylinders seals etc. But I'd never fit them dry. You can pretty much guarantee they'll come adrift from their seating during installation.
 

Not replaced twice with stock. Once I get the ones from Triumph that had to be shipped from England, for 'Pete's" sake, we can go on to exploring "something else" being wrong.

Pretty sure I got the complications of o-ring installation down. It's "recurring" only if you include a temporary solution that proved not to work. Had it worked then great, and others might have benefited from the information while they waited weeks for Triumph to send o-rings. My bike, like many, is not an occasional weekender.

To recap- some o-rings failed (not in itself so uncommon is it- really?).
The stock ones I removed were a bit stiff.
I had to wait on stock replacements so I got "creative" (I won't stop riding because of the unavailability of two $1.00 o-rings).
That held for a while, then also eventually failed.
Next, install two factory o-rings that have arrived. See how that holds.
 
Last edited:
quit messing with it
if the case has a ridge to hold the sensor then place the oring in the case then use something to lube the oring and the sensor push in careful.
use one oring.
if case does not have a ledge that holds oring then place oring on sensor
 
TURBO200R4 said:
quit messing with it
Click to expand...
??? Messing with it to get it to stop leaking while waiting for stock part to come in. ???
TURBO200R4 said:
if the case has a ridge to hold the sensor then place the oring in the case then use something to lube the oring and the sensor push in careful.
Click to expand...
No ridge- smooth
TURBO200R4 said:
use one oring.
Click to expand...
Triumph put in two- parts diagram shows two. There were two on my stock bike. I used one when going non-stock, because it was fatter and taller and felt like a better fit, actually.
TURBO200R4 said:
if case does not have a ledge that holds oring then place oring on sensor
Click to expand...

  • Yes, O-ringS goes on sensor, then slide in. Lubricate with motor oil, don't force, don't nick, yes, yes....

Somehow, , there are some misunderstandings. Purpose of my post (not how to install an o-ring).....

  • IF you see an oil leak in the 2.5s check the gear position sensor. Mine started leaking. This is behind a cover you have to remove. It's not obvious, so good place to look. This is the main purpose of my post.
  • Someone else here had a leak and took it to the shop to get diagnosed and fixed (o-rings) $$$. Locating the leak, installing the o-ringS, once you have them, and assuming that you know how to install o-rings in the first place (I think most people do), is far easier than changing your oil, for example. Hope this helps someone.
  • The original two O-ringS were fairly stiff. Changing them with anything else (non-stock) has an effect (temporary in this case), so yes it's very likely the o-rings.
  • IF this happens to you don't expect to walk into a Triumph dealership to acquire these $1.05 O-rings. They can not afford to keep such things in stock!
  • I tried going with what I could find from auto parts stores and Harbor Freight until mine were shipped overseas. I ride nearly every day. Nothing I found is an exact replica, so I tried something else that worked - until it didn't about 1500 miles later. I "messed with it" and rode while the two stock ones sailed overseas. Ignoring it while waiting for the partS was not an option.
  • I'm now, most recently, simply sharing that going non-stock (for me, anyway) was just a temporary solution. This isn't "round two" with stock o-ringS.
  • Despite being temporary, this solution allowed me to continue to ride while waiting for the o-ringS without a leak for several weeks and many many miles, but NOT a permanent solution.
  • My O-ringS from Triumph have both come in. I need to get over there and then install them. That should be the fix, at least for the next 34,000 miles I hope.
 
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