Countershaft seal

[Chicken man]

Hows it goin guys. Having issues getting my countershaft seal to stop oil seeping. New orings, what appears to be a good shaft, new collar and seal. I have no explanation for this and it seems to be a very common problem. Any suggestions are welcome. Im picky. I don't ride em if they leak

[KDXGarage]

which year and model??

[Chicken man]

2002 kdx220 r

[KDXGarage]

Do you have the sprocket back on?

[Chicken man]

No. Lol. I think its dead. Ive tried everything ive seen. New collar, 3 different seals, 3 sets of orings and none of them helped

[KDXGarage]

I have read that after the sprocket and circlip are on, it puts pressure on the o-rings to keep it from leaking. I know my '94 leaked one time when I didn't have the circlip or sprocket / circlip on.

[Chicken man]

Ok. Thats a new one. Worth a shot i suppose. I didnt consider that. That's my last hope. After that im gonna have to walk away from it. Sometimes projects dont work out no matter what you do

[KDXGarage]

and DO try to install a new OEM circlip

[Chicken man]

Thats a problem too. Ive already bent 2 clips trying to get em on. Time to walk away. Very very frustrated

[KDXGarage]

were you using circlip pliers?

[Chicken man]

No my dumb a** tried using pliers and screwdrivers. Stupid because I knew better

[JoKDX220r]

If it still leaking after you put the sprocket back, try putting a shim behind the sprocket to put "more pressure", that's the only way mine stop leaking.

[KDXGarage]

Before breaking down and buying circlip pliers, I was a cussin' and a fussin' just like you.

[ericr]

That's what I found to be true too - when assembled correctly, the sprocket is putting a bit of pressure against the bushing. Also, be careful driving in the seal. It only needs to be flush against the case. Use all new parts, lube them up and twist the bushing as it goes into the seal. The o-rings can hang up to where the bushing doesn't fully seat. You'll know this if you can't get the sprocket down far enough for the circlip to go on. Get the pliers and go for it.

[KDXGarage]

Yes, don't drive the seal in too far. (AKA, don't be like me)

[kdxdazz]

the circlip must create pressure on the sprocket for it to seal,try putting feeler gauges between the circlip and sprocket to see if there is any gap,if there is any gaps there are 2 ways to fix it,first buy an o ring which is slightly thicker than the original or you can use some sort of shim or thin washer to create pressure,remember there must be pressure or it will leak

[Chicken man]

This is good to know. Thanx guys. Ill try that before judging. That may be the problem

[buck707]

https://thumpertalk.com/forums/topic/55 ... ing-cases/