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I replaced the seal twice on my '03 220 and it still leaks. Wth am I doing wrong? I used the All Balls kit 25-4036, with new O-rings, collar, and "upgraded" seal. I did the procedure according to the Cyclepedia manual. I made sure to go slow and push the seal in a little at a time, and it was seated in correctly. Made sure to oil the o rings too. The collar snugged right up to the sprocket and the circlip snapped in place. I just don't get what Im doing wrong here.

Sounds like you di it right. I had the same issue. Wound up buying a new seal and it stopped leaking. Maybe there is that much slop in the seal manufacture? Dunno'.

Figure out if its the seal or O rings leaking. If it's inside the collar its the O rings.

How far in did you push the seal?

KDXGarage wrote: 09:22 am Oct 18 2021 How far in did you push the seal?

This is prob the only thing it could be. I will have to check again but I remember it being almost flush with the case.

Are you greasing the seal lips and collar when you install?

I've got the same problem with both my bikes now after just a couple years on all OEM parts. I wonder how common of a problem this is. Please let us know what you find out.

I wonder if the countershaft bearing itself is worn, if it'll let the shaft kinda "wobble" in there and cause the seal to fail prematurely?

Is there any side to side movement of the sprocket,everything fits tight ?
Recently had the same problem with a friends WR250F with the ALL Balls kit, kit didn't stop the leak, turns out the O-Rings were the too thin, wrong thickness..
If this is the case order OEM or look locally for a seal shop. I have one that I have been dealing with locally for over 30 years for almost all seals and o-rings, equal or better then OEM quallity and much better pricing, can even get in high temp, silicone or viton if needed.

OEM KDX oring prt #92055-035 is 22x25mm and the seal prt# 92050-33 is 30x40x7mm double lip..

Did you ever try it with OEM parts?

KDXGarage wrote: 06:07 am Oct 20 2021 Did you ever try it with OEM parts?

No I did not. However I think I found something. The Cyclepedia manual shows the seal at the edge of the case. I believe this seal needs to be pushed slightly below the edge. I took a pic of where I have it now, and at rest she is not leaking. Will have to do a ride later to see if its tight.

There is no side or up/down play. My chain is not too tight either. Maybe the "upgraded" seal needs to seat further in. Thats the only thing I can think of at this point.

That seal is pushed in WAY too far. Should be flush with the outer lip.

yep. that is the problem

Yup, flush with the case.

The pic is from AFTER replacing the seal that was flush with the case. I moved it in maybe 1/8" in (from flush). It has not leaked since, but I haven't had a chance to ride it yet. Will report back after a good ride this week.

Just lean it way over to the left. You'll find out quick instead of loading it up and finding out your ride is over.

Its supposed to be flush with the case. If it leaks when it's installed correctly, something is wrong. If you push it in too far, it won't allow enough oil to hit the backside of the seal and you'll burn it up in short order. It needs lubrication to slip on that collar as the bike runs.

Slick_Nick wrote: 09:16 am Oct 25 2021 Its supposed to be flush with the case. If it leaks when it's installed correctly, something is wrong. If you push it in too far, it won't allow enough oil to hit the backside of the seal and you'll burn it up in short order. It needs lubrication to slip on that collar as the bike runs.

Thanks Nick. I didn't push it all the way in. Its barely below the case by maybe an 1/8". I understand that pushing it in too far will do damage. Thats why I was super careful. There looks to be enough room to seat it slightly in the case. After 2 tries, this is the first time its holding oil.

Eh, I think you'll be fine. You should still get oil to the back of the seal when running and leaning to the left so I, personally, wouldn't worry.

Three, 30 min rides. All seems fine and no leaks. Will keep an eye on it tho.