Hey guys, I've been restoring this kdx for awhile now and it has been a can of worms as I get one thing fixed and something else goes down. I'm currently fighting the counter shaft seal replacing it twice. It starts off fine not leaking, then as I ride it it progressively gets worse. I've been told to try rtv sealant but don't really think that will solve the problem as I feel like the rubber is giving out. Any idea would be great, I reordered two more seals to give it a go again this week.
Here is a pic of the bike completely restored. I just finished the plastics graphics and replaced the water pump shaft this week.
Counter shaft seal leak
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Counter shaft seal leak
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- KDXGarage
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Re: Counter shaft seal leak
Looking good. Any play in the bearing for the output shaft?
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- SS109
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Re: Counter shaft seal leak
I would bet on some output shaft bearing play is the issue.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
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Re: Counter shaft seal leak
I've taken it apart again. The collar over the output shaft has some grooves. The other thing I found and that I'm confused on is the o-ring that goes on the counter shaft before the collar. When I took it apart it had two. In my service manual it shows only one so I only replaced the one. I went to Rockie mountain ATV and the exploded view shows 2! Arg! I'm assuming this could be my main problem. I've attached the pics of the collar. Not sure if it needs to be replaced. I ran my fingernail over it and it his a little groove but it doesn't catch at all. I also checked my output shaft, it has no up down or side to side play. It does however goes in and out about an 8th of an inch.
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- bufftester
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Re: Counter shaft seal leak
There should be 2 o-rings behind the collar. You should also use a new snapring on the countershaft sprocket. Finally, depending on the make of sprocket you use you may need to place a shim between the collar and the sprocket. There should be no in/out play of the collar when installed.
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Re: Counter shaft seal leak
Replace the collar, o-rings and circlip when replacing the seal.
Yes, that collar is shot.
Yes, that collar is shot.
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Re: Counter shaft seal leak
The All Balls kit comes with a new collar--I'm guessing that collar is your issue.
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Re: Counter shaft seal leak
https://www.allballsracing.com/25-4036.html
Unfortunately it's out of stock like almost everything else right now it seems...
Unfortunately it's out of stock like almost everything else right now it seems...
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Re: Counter shaft seal leak
I suggest you get an OEM part.
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