Kawasaki KLR 650 Forum - Reply to Topic
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

Thread: 1984 kl600 output shaft seal Reply to Thread
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  Topic Review (Newest First)
11-10-2018 07:59 PM
1984klr600a1 Thanks everyone for there ideas.
I gave it a lot of thought about different ways of doing it. Of course the best way would be to disassemble and machine. I would have liked to do that, but I was worried about finding parts. As everyone knows, you never know what your going to find when you break into and engine. Anyways, I used a dremel and took my time.
I put everything back together this morning and went for a quick ride. So far, so good. I hope I didn't just jinx it. I'm going to take it for a longer ride tomorrow morning after I fire up my smoker for a 12 lb brisket. Again, thanks everyone for there help.
Tom, Thanks for posting pictures for me and all your help. This forum is awesome.
11-10-2018 06:51 PM
pdwestman To the untrained eye or one not familiar with KLR600's or no service manual in hand, one would not know that that is not 100% factory!

Great Job!!
11-10-2018 09:36 AM
Tom Schmitz I’m on a 10 day ride through New Mexico and Arizona and only have a phone, so can’t do the usual embedding via Flickr.

Photos are attached.

Looks like a nice job done.

BTW, I got two emails with the same photos in both emails.
11-09-2018 08:36 PM
1984klr600a1 Update,
I just ground off the lip and installed a new seal. I put a little sealant around the outside. I'm going to let it cure overnight and finish up tomorrow. Fingers crossed. I'll email Tom and see if he can post some pics.
10-23-2018 09:58 AM
pdwestman I would lay the bike down on its RH side to see better & have more control of the tool. Remember to grease the damaged seal area to keep the chips out. And remember to wear your safety goggles when grinding off the lip & blowing away the debris. You'll do fine.
10-22-2018 09:02 PM
1984klr600a1 Ok, thanks.
I'll keep you guys posted on the project. Not sure when I'm going to tackle this. I'm a little nervous.
10-22-2018 05:22 PM
pdwestman Correct, TOO deep.

On the 650 case the seal needs to be Flush/Level with the Exterior surface of the case. Once you grind off the Stupid retainer lip on your 600 case, its seal will be Flush/Level with the case. Correct?

Do NOT insert seal below level!

Engine oil must be allowed to enter the 4 scallops of the spacer collar to enter the hole in the transmission shaft to feed the 3 free-spinning gears & the kickstart gear. The o-ring in the groove of the transmission shaft seals the interior of the collar to prevent oil leaking out between the collar & the shaft.
10-22-2018 04:33 PM
1984klr600a1 Pdwestman,
Just to be clear.
The first 4 pics are from my bike, kl600. The next 2 pics are from the 650. Tom posted all of them as I'm having a problem posting pics. Are u saying the second set of pics(2 of the 650), the seal is too deep?
10-22-2018 11:56 AM
Tom Schmitz Yes, in the other thread I provided him with your post on flush installation.
10-22-2018 10:42 AM
Originally Posted by 1984klr600a1 View Post
I can't believe that kawasaki engineers would design a wear part like that. Morons. Man, if I had it apart, it would be an easy fix. I run a big vertical lathe at work. Anyways, im thinking of the best way to do it in the bike. Tool? Any thoughts?
Die Grinder or Dremel Tool. Pretend that you are a dentist for while and be careful. If the old seal has a gap around the collar just put some grease around it.

Just to be clear, the pics which Tom just provided are of a KLR650 which the oil seal was installed TOO Deeply.
I don't think that Tom was encouraging you to attempt to grind out your case seal pocket to look like that.

I'll say again, just make it flush.
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