KDXRIDER.NET

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.

Looking good. Any play in the bearing for the output shaft?

I would bet on some output shaft bearing play is the issue.

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.

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.

Replace the collar, o-rings and circlip when replacing the seal.

Yes, that collar is shot.

The All Balls kit comes with a new collar--I'm guessing that collar is your issue.

https://www.allballsracing.com/25-4036.html

Unfortunately it's out of stock like almost everything else right now it seems...

I suggest you get an OEM part.