New Countershaft Seal kit but still leaks
- TwistedRoot
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New Countershaft Seal kit but still leaks
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.
2002 KDX 200
2003 KDX 220
2003 KDX 220
- doakley
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Re: New Countershaft Seal kit but still leaks
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'.
- Slick_Nick
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Re: New Countershaft Seal kit but still leaks
Figure out if its the seal or O rings leaking. If it's inside the collar its the O rings.
'00 KDX 220R
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Re: New Countershaft Seal kit but still leaks
How far in did you push the seal?
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- TwistedRoot
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Re: New Countershaft Seal kit but still leaks
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.
2002 KDX 200
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- Slick_Nick
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Re: New Countershaft Seal kit but still leaks
Are you greasing the seal lips and collar when you install?
'00 KDX 220R
- ericr
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Re: New Countershaft Seal kit but still leaks
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.
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- Slick_Nick
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Re: New Countershaft Seal kit but still leaks
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?
'00 KDX 220R
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Re: New Countershaft Seal kit but still leaks
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..
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..
02 KDX220
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Re: New Countershaft Seal kit but still leaks
Did you ever try it with OEM parts?
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- TwistedRoot
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Re: New Countershaft Seal kit but still leaks
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.
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2002 KDX 200
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- Slick_Nick
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Re: New Countershaft Seal kit but still leaks
That seal is pushed in WAY too far. Should be flush with the outer lip.
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Re: New Countershaft Seal kit but still leaks
yep. that is the problem
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- Molly's 70
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Re: New Countershaft Seal kit but still leaks
Yup, flush with the case.
If you lend someone $20, and never see that person again, it was probably worth it.
- TwistedRoot
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Re: New Countershaft Seal kit but still leaks
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.
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Re: New Countershaft Seal kit but still leaks
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.
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- Slick_Nick
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Re: New Countershaft Seal kit but still leaks
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.
'00 KDX 220R
- TwistedRoot
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Re: New Countershaft Seal kit but still leaks
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.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.
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- SS109
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Re: New Countershaft Seal kit but still leaks
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.
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- TwistedRoot
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Re: New Countershaft Seal kit but still leaks
Three, 30 min rides. All seems fine and no leaks. Will keep an eye on it tho.
2002 KDX 200
2003 KDX 220
2003 KDX 220