1984 kl600 output shaft seal - Page 2 - Kawasaki KLR 650 Forum
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

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post #11 of 19 Old 10-22-2018, 11:56 AM
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Yes, in the other thread I provided him with your post on flush installation.

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“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #12 of 19 Old 10-22-2018, 04:33 PM Thread Starter
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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?
Tim
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post #13 of 19 Old 10-22-2018, 05:22 PM
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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.

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post #14 of 19 Old 10-22-2018, 09:02 PM Thread Starter
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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.
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post #15 of 19 Old 10-23-2018, 09:58 AM
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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.

pdwestman
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post #16 of 19 Old 11-09-2018, 08:36 PM Thread Starter
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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.
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post #17 of 19 Old 11-10-2018, 09:36 AM
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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.
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File Type: jpg 410D49FA-6F48-4B51-B4A4-3519F4D176E0.jpg (489.6 KB, 6 views)
File Type: jpg C9AEE49F-915F-4A3C-9C1C-CF1552B52A90.jpg (528.7 KB, 7 views)

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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 11-10-2018 at 09:41 AM.
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post #18 of 19 Old 11-10-2018, 06:51 PM
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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!!

pdwestman
Modify at "YOUR OWN RISK"!

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post #19 of 19 Old 11-10-2018, 07:59 PM Thread Starter
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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.
Tim
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