How to replace final drive seal on a 05 Kx250f

[D3ALN]

Does anyone know where there is a step by step guide? Would like to have a go at doing myself.

[Max Preload]

Pretty straight foward.

Take off the cover. Remove the sprocket. Pry the seal out with a small screwdriver being careful not to damage the case working around the circumference to make it easier for yourself. Make sure the spring gaiter comes with the seal or is removed from the shaft if it falls off.

Apply a light coat of clean oil around the new seal outside and inside edges, gently fit it square and push it evenly in with a socket (if you have one that's just smaller than the OD of the seal and deep enough to go over the final drive shaft) or just use a 3/8" drive extension to apply pressure around the outside edge of the new seal pushing it into the housing in a pattern as if you were tightening wheel nuts on a car.

[D3ALN]

Pretty straight foward.

Take off the cover. Remove the sprocket. Pry the seal out with a small screwdriver being careful not to damage the case working around the circumference to make it easier for yourself. Make sure the spring gaiter comes with the seal or is removed from the shaft if it falls off.

Apply a light coat of clean oil around the new seal outside and inside edges, gently fit it square and push it evenly in with a socket (if you have one that's just smaller than the OD of the seal and deep enough to go over the final drive shaft) or just use a 3/8" drive extension to apply pressure around the outside edge of the new seal pushing it into the housing in a pattern as if you were tightening wheel nuts on a car.

cheers top man

[Max Preload]

Pry the seal out with a small screwdriver being careful not to damage the case working around the circumferenceI should clarify. Don't attempt to put the screwdriver in between the engine case and the seal - that WILL damage the case. I just pierce the face of the seal to pry against.

[D3ALN]

I should clarify. Don't attempt to put the screwdriver in between the engine case and the seal - that WILL damage the case. I just pierce the face of the seal to pry against.

Thanks for that But i am stuck at getting the sprocket off at the moment as I dont have a circlip tool is there another way to do them?

[D3ALN]

Thanks for that But i am stuck at getting the sprocket off at the moment as I dont have a circlip tool is there another way to do them?

I got it off is it ok to hammer the screwdriver in to old seal to get off? Id say its the orginal the one in there.

[Max Preload]

I got it off is it ok to hammer the screwdriver in to old seal to get off? Id say its the orginal the one in there.Yes... but be aware there's a bearing behind there!

[D3ALN]

Yes... but be aware there's a bearing behind there!

cheers thanks for that

[D3ALN]

I have replaced the seal but can not get the thing that goes round haft in as much as it should be how can i do this I am starting to put all back together

[Max Preload]

I have replaced the seal but can not get the thing that goes round haft in as much as it should be how can i do this I am starting to put all back togetherI don't understand.

[D3ALN]

I don't understand.
sorry there is a piece of pipe that goes round the shaft in the inner diameter of the seal. It needs to go firther in but i cant get it to go do you have any tips and or tricks to do it. Asat the moment when I out the sporocket on it sits out too far and I cant get the circlip in the indent. Hope this makes sense

[Max Preload]

sorry there is a piece of pipe that goes round the shaft in the inner diameter of the seal. It needs to go firther in but i cant get it to go do you have any tips and or tricks to do it. Asat the moment when I out the sporocket on it sits out too far and I cant get the circlip in the indent. Hope this makes sense
Part #92152A? (http://www.bikebandit.com/houseofmotorcycles/2005-kawasaki-kx-250f-transmission/o/m3846sch434224)
There doesn't seem to be any special trick - it's just a plain collar. But why did you take it out?

[D3ALN]

Part #92152A? (http://www.bikebandit.com/houseofmotorcycles/2005-kawasaki-kx-250f-transmission/o/m3846sch434224)
There doesn't seem to be any special trick - it's just a plain collar. But why did you take it out?

Took out to get seal out will have another go at it tonight

[scott411]

Took out to get seal out will have another go at it tonight

ok there should have been an oring behind spacer, make sure that is not folded preventing the spacer going back in,

[Max Preload]

ok there should have been an oring behind spacer, make sure that is not folded preventing the spacer going back in,I think you'll find, since the two o-rings are the same part number, that they're both inside the collar and on the smooth machined section of the output shaft or there would be a path for oil to exit/dirt to enter the box along the outside of the final drive shaft and under the collar.

I'd say the o-ring just isn't over the step in the shaft yet.

If there's a metallic noise as it bottoms out as it currently is (i.e. proud of the spline so you can't get the sprocket on) then it possibly needs to go inside a rebate in 13262E. I doubt that though as that would be rather crude given that gear spins independant of the shaft until dogged. I suspect that the gear has simply slid along a little and the gearbox is actually in 2nd not neutral as it should be and the dog needs to be returned to neutral with the shifter.

I would simply check the gearbox is in neutral, remove the collar and inspect the o-rings then lubricate with clean oil and push it on evenly.

[D3ALN]

i think I need to get the new seal back out and have a look at for these orings you talk about how do i get it out without damaging it

[Max Preload]

Withdraw the collar and have a look for the o-rings. I'm thinking they'll be inside it.

If you have to remove the seal try to gently lever it from behind with the collar out.

[D3ALN]

Cant find the said orings. wrecked ,my new seal getting it out to look but have worked out where i went wrong. cheers for the help

[D3ALN]

ALL COMPLETED READY TO RIDE AGAIN thanks again for the help

[Max Preload]

Can't find the o-rings, eh... that'd be bad. How is the collar sealed against the shaft?

[D3ALN]

Found them when I put it all back together its all sorted