Countershaft seal leak - Kawasaki KLR 650 Forum
Go Back   Kawasaki KLR 650 Forum > KLR 650 > 1987 to 2007 Wrenching & Mods

1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

LinkBack Thread Tools Display Modes
Old 01-03-2008, 06:11 PM
Join Date: Jan 2008
Location: Barrie, Ontario CANADA
Posts: 8
Default Countershaft seal leak

I just noticed some oil drips this had been parked for 6 months...I cleaned out the carb, put in some fresh petrol and was out for a ride. Went 10 miles or so....really cold temps. this a.m. 18f. I stopped into a KAWASAKI dealership, went in for a chat ...and when I came out found a puddle of oil! A mechanic there said it could be a countershaft seal leak. If it is, what's the procedure. I have no manual....yet.
Reply With Quote
Sponsored Links
Old 01-03-2008, 06:35 PM
DXKLR's Avatar
Join Date: May 2007
Location: Richmond, Ky
Posts: 1,980

This is a procedure I found in another forum. Looks pretty good.

Here is link for pics:


1. Remove sprocket cover (3 6mm bolts, w/ 10mm heads)
2. Remove large keeper nut, washer and sprocket, and chain.
Usually you can pop the chain off the sprocket, and tuck the chain out of
the way against the swingarm. You'll need to flatten out the washer with a
punch and hammer. The large nut requires a 27mm hex socket, or you
can get by with a 1-1/16" socket.
3. The oil seal is inside the left half of the crankcase, but usually comes
out pretty easily. I bent a small screwdriver to use as a removal tool.
Pry on the front, then back, then top, then bottom, repeat, seal is out.
Place seal in discard pile.
4. On the countershaft, there will be a collar. Remove the collar and
check to see that it is not excessively worn or grooved from the seal.
If it is worn you should replace it.
5. On the countershaft, behind the collar, there will also be an O-ring.
Remove the O-ring and set in the discard pile.
6. Clean the countershaft and the seal surfaces with WD40 and clean rags.
7. Install the new O-ring onto the base of the countershaft. I slipped it
into place with a small scrap of rolled paper acting as a sleeve.
8. Wipe the bore for the seal with clean oil, and install the oil seal with the
smooth side out. Press it into place with your thumbs. It should be FLUSH
with the surrounding case. NO gasket compound needed.
9. Dribble clean oil onto the collar, and install it onto the countershaft.
Be sure the notched end goes in first. Check the parts diagram to be sure.
10 Reinstall the sprocket and chain, and the cover. You'll need to bend the
tabs of the washer back up to hold the nut. Double check the chain
tension. I set it so that the chain just touches the swingarm, right under
the rubber chain slider (the little vertical strip w/ the screw in it)

There's a few pics of the process posted below. These are from the earlier
year bikes (1989 in the photos, the same except for the sprocket keeper)

Late model parts: I replace the O-ring and Seal when I'm in there, but
you'll want to double check the collar for wear, or the new seal will begin
leaking all too soon.
Collar 92027-1800
O-Ring 92055-1293
Oil seal 92049-1159

Check the fiche ( or your dealer to be certain on p/n. or bikebandit can sell you the stuff online.

Good luck...

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.
Reply With Quote
Old 01-03-2008, 10:38 PM
Join Date: Jan 2008
Location: Barrie, Ontario CANADA
Posts: 8

Hey DXKLR , OLD SIX FITTY . . .that is awesome information!
Thanks VERY MUCH! Having no manual /parts book as yet, I really appreciate the parts numbers and pictures....
THE PICTURES ARE FABULOUS.....step by step...
BTW mine's an '89.
Most appreciated! -Chris

Last edited by nesster; 01-03-2008 at 10:44 PM.
Reply With Quote
Old 01-03-2008, 11:12 PM
DXKLR's Avatar
Join Date: May 2007
Location: Richmond, Ky
Posts: 1,980

You need to go to this link also for mods that should be done asap

Ole SIX FITTY is another guy on another forum, I just happen to come up on that a lil while back and I printed it out and put it into my KLR binder.
2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.
Reply With Quote
Old 01-04-2008, 12:35 AM
SLO-KLR's Avatar
Join Date: Sep 2006
Location: Paso Robles, CA.
Posts: 1,333

Before you jump into changing the seal make sure the chain isn't too tight and the nut on the countershaft sprocket is torqued properly. These two things can often cure a minor leak.
Reply With Quote
Old 03-24-2008, 01:48 PM
Join Date: Jan 2008
Location: Barrie, Ontario CANADA
Posts: 8
Default countershaft oil leak

Well I finally got around to searching for the 3 parts...
found these two: 92027-1800 "collar"
92055-1293 "O-ring"
at Bike

....but nobody (so far) has the "oil seal" no. 92049-1159

Does anybody out there in KLR forum land have advice
as to where to look for this? Where do all you KLR folks order
parts from?

Thanks..-Chris .....
Reply With Quote
Old 03-26-2008, 11:42 AM
Join Date: Sep 2006
Location: Elk Grove, Ca
Posts: 990

I just replaced mine..I want to say I got it from .

If that doesn't work, will have it. They have the KLR listed as a KL650. They're super slow on parts delivery though.

In my experience you probably don't need the O-ring and collar, just get the seal. If it still leaks, get the collar...the O-ring is a non-wear item.
Originally Posted by Swish~Married View Post
Larryboy, you're brilliant!!

Last edited by larryboy; 03-26-2008 at 11:44 AM.
Reply With Quote
Sponsored Links

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
Gas tank leak mrweasel2 1987 to 2007 Wrenching & Mods 8 04-16-2010 08:10 PM
Prevailing Torque Countershaft Nut TheWanderer 1987 to 2007 Wrenching & Mods 3 08-09-2008 11:04 PM
Chip Seal flash Deep South Riders 11 08-09-2008 08:29 AM
gas leak mjkmarine1277 1987 to 2007 Wrenching & Mods 1 06-20-2008 10:23 PM
countershaft oil leak nesster KLR & Other Motorcycle Related Discussion 9 03-27-2008 08:28 AM

All times are GMT -5. The time now is 03:22 PM.

Powered by vBulletin® Copyright ©2000 - 2015, Jelsoft Enterprises Ltd.
SEO by vBSEO 3.6.1
Motorcycle News, Videos and Reviews
Honda Grom Forum Harley Davidson Forum Honda 600RR Forum Kawasaki Forum Yamaha R6 Forum Yamaha FZ-09 Forum
1199 Panigale Forum Honda Africa Twin Forum Roadglide Forum Honda CBR1000 Forum Vulcan Forum Yamaha R1 Forum Yamaha R3 Forum
Ducati Monster Forum Harley Forums Honda CBR250R Forum ZX10R Forum Star Raider Forum Yamaha Viking Forum
Suzuki GSXR Forum V-Rod Forums Honda Shadow Forum Kawasaki Motorcycle Forum Star Warrior Forum KTM Duke 390 Forum
SV650 Forum BMW S1000RR Forum Honda Fury Forum Kawasaki Versys Forum Drag Racing Forum Ducati 899 Panigale Forum
Suzuki V-Strom BMW K1600 Triumph Forum Victory Forums Sportbikes BMW NineT Forum
Volusia Forum BMW F800 Forum Triumph 675 Forum MV Agusta Forum HD Street Forum Suzuki GW250 Forum
Yamaha Motorcycles Victory Gunner Forum Victory Charger Forum Honda Vultus Forum HD LiveWire Forum Ninja H2 Forum
BMW Scrambler Forum Ducati Scrambler Forum Kawasaki Ninja 250SL Forum