Countershaft seal replacement problem - collar stuck - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
LinkBack Thread Tools Display Modes
post #1 of 3 Old 10-24-2016, 08:39 PM Thread Starter
Neutral
 
Join Date: Oct 2016
Posts: 1
Countershaft seal replacement problem - collar stuck

Hi Folks,

I'm attempting to fix a countershaft seal leak for my Gen 1 KLR650 (2006). Upon pulling the countershaft sprocket it was clear the seal was half out of the case -- hence the major oil leak. I purchased the seal and the o-ring that is behind the collar for the repair.

I can't figure out how to remove the collar. Everything I've read indicates it should easily slide off of the countershaft. While I could just clean the surface and install the new seal (without pulling the collar and replacing the o-ring), I'd rather pull it and inspect it to avoid having to get in there again. I'm not really sure what the collar does and whether it's being stuck contributed to the problem.

Anyone have a solution? I'm thinking a dental pick to get behind it and pull it out. OTOH -- I don't want to create a problem. There is some rust on the collar face (not the sealing surface). I think the collar to shaft doesn't need to move and forcing it out might damage that surface. Leave it alone or remove it?

Thanks!
ssfx is offline  
Sponsored Links
Advertisement
 
post #2 of 3 Old 10-24-2016, 08:57 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,615
Quote:
Originally Posted by ssfx View Post
Hi Folks,

I'm attempting to fix a countershaft seal leak for my Gen 1 KLR650 (2006).

I purchased the seal and the o-ring that is behind the collar for the repair.

I'm not really sure what the collar does and whether it's being stuck contributed to the problem.

Anyone have a solution? I'm thinking a dental pick to get behind it and pull it out. OTOH -- I don't want to create a problem. There is some rust on the collar face (not the sealing surface). I think the collar to shaft doesn't need to move and forcing it out might damage that surface. Leave it alone or remove it?

Thanks!
ssfx,
The 'o'-ring is in a groove, recessed half way into the shaft. It is Not between the collar and the bearing like 2 stroke dirt bike. The collar slips Over the 'o'-ring. And it can get a pretty good grip!

I suggest if the seal was the problem, leave the collar and 'o'-ring alone.

The collar has 4 crescents cut into the back face to allow oil to be pressure fed thru a hole and into the center of the transmission shaft. The output bearing has a built-in seal to ensure the oil go's into the shaft. DO Not damage that seal on that bearing! It could result in total engine tear-down.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
post #3 of 3 Old 10-25-2016, 01:37 PM
4th Gear
 
GoMotor's Avatar
 
Join Date: May 2014
Location: Texas
Posts: 1,261
I had that seal pouch out some and leak oil in Grants Pass, OR on my way back to Houston from Port Orford, OR. I pushed it back in and watched it closely for a while. It worked fine with not a drop of leak all the way home. Just to be on the safe side I installed a new seal in Houston, but never touched the collar/o-ring. With more than 10K miles since there is still no leak.
GoMotor is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Rebuilding the forks -- which way does the collar at the bottom face? drumstyx 1987 to 2007 Wrenching & Mods 0 07-07-2016 08:16 PM
Water Pump seal(s) replacement tomatocity 1987 to 2007 Wrenching & Mods 11 09-27-2009 09:16 PM
countershaft oil leak nesster KLR & Other Motorcycle Related Discussion 9 03-27-2008 09:28 AM
Countershaft seal leak nesster 1987 to 2007 Wrenching & Mods 6 03-26-2008 12:42 PM

Posting Rules  
You may post new threads
You may 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

 
For the best viewing experience please update your browser to Google Chrome