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Posted: **09:57 pm May 29 2025**

OK - so I finally had some time to engineer nerd out here. The drawing below has all the info and measurements I have. Use at your own risk obviously. But my plan is to modify the groove diameter as per the drawing and give it a go! I also compare used stock measurements to Fredette's oring and to the 008 Xring. My take is use the Fredette's solution, or the Xring, or keep searching for the unicorn packing. Mine will be in the machinists hands tomorrow. If any one is interested, I'm happy to share the SolidWorks files, or as STL / STEP files, and the actual PDF of this drawing. Just PM your email and I'll fire it off............ Cheers - Robert

Posted: **10:04 pm May 29 2025**

: KDX Packing Info.JPG (149.72 KiB) Viewed 54752 times

Posted: **01:13 pm May 30 2025**

Excellent work! Thank you, sir!

Posted: **06:32 pm May 30 2025**

Kawibunga. that's a neat summary drawing. Thank you! Curious to hear any feedback from the machinist that will cut the groove.

Posted: **02:08 pm May 31 2025**

billie_morini wrote: 06:32 pm May 30 2025 Kawibunga. that's a neat summary drawing. Thank you! Curious to hear any feedback from the machinist that will cut the groove.

The young fellow picked it up yesterday. Said it shouldn't be a problem. Their standard narrow cutter is 1/16" and the groove width is .080" so it shouldn't take any special tools. Will post how it all turns out. Just going cost me beer and chicken wings!

Posted: **02:14 pm May 31 2025**

Thanks for the update!

Posted: **11:30 am Jun 02 2025**

Kawibunga wrote: 02:08 pm May 31 2025
billie_morini wrote: 06:32 pm May 30 2025 Kawibunga. that's a neat summary drawing. Thank you! Curious to hear any feedback from the machinist that will cut the groove.
The young fellow picked it up yesterday. Said it shouldn't be a problem. Their standard narrow cutter is 1/16" and the groove width is .080" so it shouldn't take any special tools. Will post how it all turns out. Just going cost me beer and chicken wings!

I'm going to bet that my parting tool bit (tall skinny cutoff tool steel bit for lathe use in cutting off a section from the end of a lathe turned work piece) will do nicely. I'll probably finish it off with a piece of emery cloth folded in a U-shape to deburr/polish it.

Posted: **01:49 pm Jun 30 2025**

Kawibunga, that technical drawing is awesome. thank you for taking the time to make it!

I just wanted to stop by and say my ebay 5x8 red silicone O ring is still holding up. I think it has about 40 hrs on it now and has seen some really high coolant temps and hard running in muddy enduros. I'm tearing the motor down due to a crank seal leak, but the Fredette-inspired economy fix is still holding back air pressure when leak tested @ 5 psi. No visible wear or marring on the O ring.

I've recently acquired a few O rings of the same size made from buna. I will probably try one of these out when i reassemble the engine, but so far the silicone seems totally adequate.

Posted: **06:51 pm Jul 01 2025**

Thanks for the report back, Jamie! I will be putting in one of these o-rings after Friday morning's ride when I tear my top end down for inspection, cleaning, piston ring end gap measuring, and cylinder bore measuring...

Posted: **01:12 am Jul 02 2025**

jamiethegiraffe wrote: 01:49 pm Jun 30 2025 Kawibunga, that technical drawing is awesome. thank you for taking the time to make it!

I just wanted to stop by and say my ebay 5x8 red silicone O ring is still holding up. I think it has about 40 hrs on it now and has seen some really high coolant temps and hard running in muddy enduros. I'm tearing the motor down due to a crank seal leak, but the Fredette-inspired economy fix is still holding back air pressure when leak tested @ 5 psi. No visible wear or marring on the O ring.

I've recently acquired a few O rings of the same size made from buna. I will probably try one of these out when i reassemble the engine, but so far the silicone seems totally adequate.

Thank you, Jamie Giraffe. This is good news from someone that understands performance and bench testing.

Posted: **06:37 pm Feb 07 2026**

While the dimensions were on here as measured on at least 3 different NOS and used KIPS packing seals, as measured by at least 2 different forum members, I've had the part # on my eBay saved search alerts for ages now, & one just popped up NOS in OEM packaging from a dealer in Canada, & I decided to jump on it in order to get my hands on an unused one for my own references.

: KIPS-packing_seal1.jpg (231.03 KiB) Viewed 19471 times

: KIPS-packing_seal.jpg (107.16 KiB) Viewed 19471 times

I have several of the silicone o-ring substitutions to use, which were graciously sent to me by no less than TWO different generous forum members participating in this thread, as they typically are so low priced that you must order a minimum quantity of them for the sellers to make any profit. Thanks Jamie & Billie! This NOS packing seal that I should have from Canada soon may just remain a reference piece.

https://www.ebay.com/itm/366182522502

In looking up this thread, I happened upon a 2007 thread from the infamous CanyonCarver,,
viewtopic.php?t=3727
where he said he ordered two of these on an OEM parts order through his local Kawasaki dealership, but instead, received 2 separate smaller X-rings per each single KIPS packing seal ordered...???!!!
REALLY? So Kawasaki may have briefly been substituting two off-the-shelf X-rings to replace one single packing seal...??? This is perhaps the biggest news on this whole 6 or 8 page thread on this part number in my view at least... Now, if we only could have gotten dimensions off of Kawasaki's substitution part before they just simply listed them as NLA?!
Perhaps there was some sort of service bulletin on this that would still be able to be be looked up in Kawasaki databases???

canyncarvr wrote: 04:12 pm Jan 18 2007 ...I just ordered the OEM stuff.

What I just got? O-rings! NOT what the bike came with! They are special O-rings, though. They look like X-rings on a chain..but the 'relief' or cut is on the outer diameter as opposed to a lateral diameter.

Posted: **10:33 pm Feb 07 2026**

Chuck, you're a god! You got one! I never even knew there was such an alert system in Ebay! I'd prolly keep it for reference, too. I might also use it's dimensions with entities like Fredette or China manufacturer to ascertain whether somebody would make new ones. I wonder if Enduralast or Caltric would make them.

But, Chuck. What I'm really trying to say is, "Gee, can I borrow it? Just for a little while. I promise to take good care of it. Honest."

Posted: **10:19 pm Mar 12 2026**

wowwww chuck found some pure unobtainium! Good idea setting the alert on ebay.

Any word back on the modified-groove with Mcmaster 008 X ring mod?
I have an extra KIPS shaft and have discovered a great local machine shop. I was thinking about cutting the extra shaft and ordering some X rings if anyone can confirm that it's working for them.

Posted: **08:47 am Mar 13 2026**

I haven't had much time yet to dedicate to KDX work in recent times, but will be making time soon.
I'll be splitting the cases on a 220 engine in the next few weeks to send the crank out to Boyko Racing for a rebuild with Wossner forged rod and crank pin + professional balancing, as well as some mild cylinder porting on one cylinder and an inspection/critique of someone else's porting work.

At some point I'll be reassembling that engine for the hybrid build project, as well as my '97 220 being overdue for a top end job as it's no longer scary fast although it starts and runs pretty well, just not as much power as 460+ hours / 5+ years ago!

For either one of those I am likely to try this machining. I need to pick up some extra power valve components as well for my 4 cylinders, and a 5th 220 or 200H cylinder at some point.

Posted: **08:55 pm Mar 13 2026**

jamiethegiraffe wrote: 10:19 pm Mar 12 2026 Any word back on the modified-groove with Mcmaster 008 X ring mod?

It's been a slow process as i haven't done any work on the bike this winter up here, BUT I'm picking up the shaft next week with the groove modification as per my drawings. I'll take some pics and post em up! Apologies for the delays but it's happening now.

Posted: **08:44 am Mar 14 2026**

Kawibunga wrote: 08:55 pm Mar 13 2026
jamiethegiraffe wrote: 10:19 pm Mar 12 2026 Any word back on the modified-groove with Mcmaster 008 X ring mod?
It's been a slow process as i haven't done any work on the bike this winter up here, BUT I'm picking up the shaft next week with the groove modification as per my drawings. I'll take some pics and post em up! Apologies for the delays but it's happening now.

Thanks for the drawing! I'll be chucking mine up in the lathe and doing this modification next time I have the top end apart.

Posted: **10:01 am Mar 14 2026**

If anyone has a couple of spare 008 X rings they want to send me I will also cut the powervalve shaft groove and proceed with this mod. I may bite the bullet and order from McMaster, but that $13 shipping charge on a bag of 50 is tough to swallow!

Posted: **10:30 pm Mar 14 2026**

jamiethegiraffe wrote: 10:01 am Mar 14 2026 If anyone has a couple of spare 008 X rings they want to send me I will also cut the powervalve shaft groove and proceed with this mod. I may bite the bullet and order from McMaster, but that $13 shipping charge on a bag of 50 is tough to swallow!

I'll split a 50 bag with you, Jamie... We'll just have to agree on the best choice of X-ring material! I'd take maybe 10 and split the shipping and purchase costs if you wanted to receive and ship them out to me and perhaps Kawibunga.

I'll be finding time to dismantle and split my old 220's cases very soon to send out the crank and a few cylinders, & time flies, so they may be arriving back before too long, & with as much house remodeling work as I have to keep me occupied in the next 6 weeks, at which point I'll be kicking myself for not ordering up some -008 X-rings already when the crSnk and cylinders arrive back here!

Posted: **11:29 am Mar 15 2026**

Sounds good to me Chuck. I'll place the order as soon as we decide on which material.
A 50 pack of Viton is the same price as a 100 ct. bag of Buna- Around $7.50 USD.
Any strong opinion? If we're already paying shipping maybe just order both?

Posted: **02:06 pm Mar 15 2026**

jamiethegiraffe wrote: 11:29 am Mar 15 2026 Sounds good to me Chuck. I'll place the order as soon as we decide on which material.
A 50 pack of Viton is the same price as a 100 ct. bag of Buna- Around $7.50 USD.
Any strong opinion? If we're already paying shipping maybe just order both?

Kawibunga wisdom says perhaps HNBR is best?

Kawibunga wrote: 11:32 am Feb 19 2025

With regards to Viton/FKM vs BUNA/Nitrile - viton is great chemically but weak mechanically. Much better chance of actually just tearing and breaking this seal during installation and wear and tear vs a BUNA/Nitrile seal - But standard Buna/Nitrile is not near as chemically & heat resistant as Viton, but the super duper version of Nitrile, Hydrogenated Nitrile (HNBR or HSN as it's called) is pretty much as good everywhere as viton, but way better mechanically. Hence my choices are HNBR/HSN - VITON/FKM - BUNA/NITRILE in that order.......... and you always want them Black, that means carbon filled and way stronger, any type of seal.

The McMaster part 6540K118 - the 008 Xring or Quad ring is EXACLTY what I want to try to get to work. It's slightly narrower but nothing I'd be worried about (instead of about .001 clearance per side on groove width, we have .004" - means pretty much nothing) My plan is to 3d print some parts and install this on it and measure the final OD with the seal on. Make sure I'm in the range, then machine the shaft groove deeper but leave the width the same, and try it!

My my last concern - which you don't have - is all though I With regards to Viton/FKM vs BUNA/Nitrile - viton is great chemically but weak mechanically. Much better chance of actually just tearing and breaking this seal during installation and wear and tear vs a BUNA/Nitrile seal - But standard Buna/Nitrile is not near as chemically & heat resistant as Viton, but the super duper version of Nitrile, Hydrogenated Nitrile (HNBR or HSN as it's called) is pretty much as good everywhere as viton, but way better mechanically. Hence my choices are HNBR/HSN - VITON/FKM - BUNA/NITRILE in that order.......... and you always want them Black, that means carbon filled and way stronger, any type of seal

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