Countershaft oil spill to rival the Exxon Valdez

[vmx1963]

Today I did something unusual – I fell off on the right-hand side (I usually drop the bike on its left side for some reason ).  Once I overcame my shock of falling to the right and picked the bike up, I was even more surprised to see a rather large pool of oil on the ground.  Leaning the bike to the right again produced another alarming pool of oil – this, I though, shouldn't be happening!  I've had leaking countershaft seals before on Huskies, but never to the extent of having oil literally pouring out when the bike is leaned over!

Back into the shed and off with the ignition cover, chain & countershaft sprocket.  Now at this point I must shamefully admit that I've never taken any notice of the countershaft seal arrangement and so seek the wise counsel of POGers more experienced than I.  All the bits seem to be in place as per the parts drawing http://members.iinet.net.au/~allantud/pics/countershaft.jpg but close inspection shows a large oil-conducting gap between the spacer and the inner seal lip – is this normal?  

Type 54 250cc

http://members.iinet.net.au/~allantud/pics/Spacer_in.JPG
http://members.iinet.net.au/~allantud/pics/Seal_close.jpg
http://members.iinet.net.au/~allantud/pics/Spacer_removed.JPG

Could the countershaft seal not be pushed in enough (it's flush with the outer case) – is it supposed to seal against the face of the inner bearing race and so do I just need to take a metric hammer and whack (!!) the seal in until it mates against the bearing?  Or is it supposed to seal against the spacer and in which case the wrong type of seal has been fitted?

I assume I should be able to pop the old seal out and just belt (!!!) in a new one (notice my delicate approach to bike maintenance)?

Any wise advice most humbly and gratefully received.  I really must order another workshop manual soon (it's still not here Larry!!!!).

Cheers

[Kip Kern]

The set up on the countershaft is: an "O" ring, then spacer, with beveled end towards engine, that is installed over the shaft and pushed in with some resistance felt.  Make sure you have the "o" ring, make sure the spacer has the bevel going towards the engine and that there is not a "groove" worn on the outer surface of the spacer from the old countershaft seal, and change the CS seal to a new one and all should be OK![8D] Next Patient!

[Speedy]

quote:Originally posted by kip kern

The set up on the countershaft is: an "O" ring, then spacer, with beveled end towards engine, that is installed over the shaft and pushed in with some resistance felt.  Make sure you have the "o" ring, make sure the spacer has the bevel going towards the engine and that there is not a "groove" worn on the outer surface of the spacer from the old countershaft seal, and change the CS seal to a new one and all should be OK![8D] Next Patient!

Totally correct.Check,clean and replace.Speedy-->>>>

Helmut Clasen KTM
162 Hillcrest Ave
L9H 4Y3
Dundas Ontario Canada
Ph.905-627-5349
[email protected]
http://speedy_c.tripod.com
Sachs GP-GS 250-7A reeds
Zuendapp 125 GS ISDT repl.73
KTM 450 EXC Auto.03
Duke spec.Edit,1996
Adventurer 02

[vmx1963]

Thank you Kip & Speedy.

Definitely missing the O ring, so that's one problem I can fix.

Kip, you ask if the outer surface of the spacer has a groove worn in it from the countershaft seal – this suggests that the seal should mate with the outer surface of the spacer yes?  Mine has a 2 – 3 mm gap between the inner lip of the seal and the spacer – so definitely no groove but which makes me wonder if the wrong seal has been installed.

I assume that when the spacer is pushed onto the countershaft, it should mate tight with the seal as well as push against the O ring?

[Kip Kern]

You are correct, you will feel resistance when you push the spacer in.  Sounds like the wrong seal has been installed.  Good Luck!