Need advice. My KLX was leaking around the countershaft seal. Its an easy replacement and I ordered a new seal, bushing, and o-ring. I replaced them and road it down the road and back and it appeared to be fixed. I went for my first offroad ride yesterday since the replacement. I never saw it leak yesterday and when I got done riding I let the bike sit on the trailer and run the carb out of gas and it did not leak. I went out tonight to take the boy for a spin in the yard on it and as I was letting it warm up I noticed it was leaking bad from the countershaft seal area. Why???

Now when I did do the install I may have made a mistake when I fired the bike up without the sprocket on the bike, the bushing spun and oil came out between the bushing and seal until the bushing worked itself all the way out. I cleaned the bushing off and put it back on and put everything back before starting again. It did not leak then till again today. So did I damage the seal by doing this?

Only other think I can think of is the possibility that the chain was to tight and damaged the seal somehow, but I would think that the shaft itself would have to bend first and I know I don't have the chain that tight.

Any suggestions? I guess order another seal and replace it and see what happens.

 

did you grease the lips of the seal? the sealing lip can burn from lack of lub on the startup/bedding in when new until the engine oil gets to the back of the seal to lub and cool.
when you started her up without sprocket and the bush walked out on you did you pull the bush and check the little O ring in behind was OK?

 

I am a bit confused on what you mean by the lips of the seal. I used an all purpose oil and lubed the outside of the seal that mates to the casing. I did check the little o-ring and it was fine.

 

The seal lips are the part that makes contact with the rotating shaft or in this case bush that turns in its centre.

 

Had time tonight to investigate the issue. Looks like I forgot to bend the lock washer over the nut and the nut and worked loose a little, which allowed the sprocket to move out some along with the bushing which I assume allowed the seal to leak. Since I already ordered a new seal I decided to go ahead and replace it again.

 

the seal seals on the bush not the shaft, if the nut is loose and the bush move out even 1/2mm the oil will leak up the centre of the bush, the o ring will only stop oil if the bush is held tight with the sprocket nut.
your seal may be ok it may only need to have the nut retightened to stop the oil.

 

I think your probably right, but since I had the bike torn down to this stage and already ordered and have the seal I am going to replace it for peace of mind. Not to mention I already buggered it up removing it.

 

well if its all ready out you may as well fit the new one,
don't forget to lock the tab