output shaft seal replacement

[Greg May]

I attached a link to one of the online parts suppliers fiche apps that shows the parts described below. I haven't yet had a leak at the output shaft ons my KLR but on a couple other Kawasaki models I've owned it has always been the o-ring. Cheap and painless repair either way....Have a great day....Greg http://www.ronayers.com/Fiche/TypeID/26/Type/Transmission/MakeID/3/Make/Kawasaki/YearID/46/Year/2005/ModelID/4275/Model/KLR650/GroupID/135389/Group/Transmission From: John Biccum To: 'Keith' ; DSN_KLR650@yahoogroups.com Sent: Tuesday, July 26, 2011 4:51:38 AM Subject: RE: [DSN_KLR650] output shaft seal replacement This is an easy and inexpensive fix. You need two parts: The seal, or as Kawasaki calls it "COLLAR,25X32X3.0", part number 92143-1721. About $9. The second part is just an o-ring, "O-Ring 21.5mm" about $5. Part number 92055-1293. I bet the O-ring could be sourced locally for a dime or two L The hardest part of the job is removing the drive sprocket. Once that is off you can remove the old seal using a small screwdriver or similar (I use a cast-off dental tool). Ensure you also remove the old O-ring. Then install the new O-ring and press the new seal into place. If you don't have a seal driver a suitable sized socket can be used as a seal driver. There is one other part that has to be removed and reinstalled, this steel part is in between the seal and the O-ring. Both the Kawasaki and the Clymer manuals show these three parts with sufficient clarity to make the job easy to understand and accomplish. From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of Keith Sent: Monday, July 25, 2011 10:26 PM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] output shaft seal replacement I looks like my output shaft seal has failed after 33k on my 05. Returned home after a 6 hour trip to find oil coating the swing arm and rear tire. Lost a good bit of oil but caught in time. Wondering what kind of job am I looking when I replace it. I have heard this can be done without removing the case, but that seems wishful thinking. Am I correct? [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]