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Hi All. I just assembled my 220 top after a refresh of rings, gaskets, & KIPS seals. Leak test shows a rapid leak somewhere but spraying soapy water at all the usual spots shows nothing. I am a bit baffled as to where the air is going. I even put plugs on the 2 coolant openings to see if it's leaking into the coolant jackets. No difference. The thread about the KIPS shaft seal has me wondering if that could be a culprit - viewtopic.php?t=26023
I will probably buy some of the recommended o-rings for that shaft and see if that helps.

Any suggestions? Am I missing something? I've done this procedure many times, but this is a 1st regarding the leak.
I did check to make sure my testing equipment is sound. All good.

Thanks for any help.

If you think it is leaking from the sub shaft seal you can remove the cover and spray water in there to check
Remember if you replace it's a packing seal and not an o ring
Did you spray the crank seals as well?

I did spray the crank seals. They are good(less than 100 hrs on them).
Sub shaft seal are new. I'll check them again.
On a different note - I saw your KIPS rattle videos, and fiddled with mine to reduce the noise. Will report back when I start it up.

Possibly between the case halves into the tranny, finger over the vent hose, spray the outer case joint halves also. There are 3 notches around the left crank bearing that were a common cause of leaks on the E series, not sure if the A and H series had the problem also.

It’ll check that too, Jimmy B.
I think I found it.
The right KIPS shaft seal seems to be ineffective.
(It is the original seal. 600+ hrs)
Will order some o-rings per the other thread.

Follow up - installed a 5 x 8 mm o-ring on the kips shaft, and that solved the air leak. Bike fired up and acted as it should. I ran only a minute or so. Will try to get out for a shakedown ride this weekend.

Eric B wrote: 12:11 pm Apr 25 2025 Follow up - installed a 5 x 8 mm o-ring on the kips shaft, and that solved the air leak. Bike fired up and acted as it should. I ran only a minute or so. Will try to get out for a shakedown ride this weekend.

This is very helpful to know. Thanks for sharing. It seems like our forum's X-ring / O-ring efforts are providing functional results.