Motorcycle Repair: 1975 cb550F handlebars/oil leak, protective sheath, seal driver

Question
Two obviously unrelated questions for you. First, can you describe the best method to change out the handlebars mainly pertaining to the wiring removal and replacement? Is it possible to keep the wiring harnesses intact?

Second, last year I had the shift shaft seals replaced due to an oil leak. Just a thousand miles later, it appears the same leak is back. Is this a common leak with this bike? What could be causing that seal to fail already? The bike shifts pretty smoothly age considered. Any tips to replacing the seals? Thanks a lot.

Answer
First the handle bar question...yes, you should be able to get the wires out without ruining them.  Lube the wires up with a light oil or soap and then start to carefully work them out of the handle bars.  The lube will help prevent the cutting of the protective sheath as you are pulling them out. Just don't start yanking on them or it will surely cut them up.  Once you're ready to put the switch wires back into a new set of bars, I usually take a piece of mechanic's wire and wrap and tape the mechanic's wire to the switch wires.  Don't make the tape wrapping too big or it won't fit back in the slot in the handle bar.  You just want to prevent the mechanic's wire from slipping off half way through the job.  When you push the mechanics wire through the handle bars it will help you pull the switch wires back down the handle bars.

Now the oil leak, I don't recall any issue with leaking shift shaft seals. It's not too difficult to to replace.  You should be able to drive a screwdriver between the seal and the shift shaft and pry out the old seal.  If you have a seal removal tool, it is less likely to scar up the seal bore or the shift shaft.  Be careful not to gouge a groove in the aluminum bore as you pry out the seal.   The new seal can be driven in with a seal driver.  Be careful not to cut the new seal lip when you put it over the shift shaft.  A piece of electrical tape over the splines will prevent any seal damage.  

Once you have the seal out look closely at the shaft and make sure it's not damaged or excessively worn.  Wiggle the shift shaft in the bore and make sure the bore is not worn to the point it doesn't hold the shaft concentric to the bore.  

Good Luck
Rich