Kawasaki KLR Forum banner

1 - 3 of 3 Posts

·
Registered
Joined
·
1 Posts
Discussion Starter #1
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!
 

·
Premium Member
Joined
·
6,667 Posts
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.
 

·
Registered
Joined
·
1,260 Posts
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.
 
1 - 3 of 3 Posts
Top