Drove my damn sprocket shaft seal too far!

I didn't know this was possible. I've never installed a seal that didn't bottom out. Well I found out the hard way. There's an open space behind where the seal sits. So while a new seal is on the way (thank you Amazon Prime) I figured I would just confirm that the seal is just installed into the outer case? this is for a 1981 KZ750E.

What a weird setup.

Hi
Do you mean #9 in the diagram below ?





That cover, called "cover, mission" in the parts diagram is not that difficult to take off. I removed mine last fall to inspect the output shaft bearing which was thankfully ok.

This is what it looks like behind the cover





If one is careful the gasket should come off with the cover but I managed to tear mine. I traced out and cut a new one from gasket paper and used a single hole paper punch for the holes

yes, #9.

I did loosen the cover bolts with success but decided draining all the oil and buying a new gasket was a bigger project than just ordering a new seal so I tightened them back up. So i'm not crazy then? That seal really just sits inside the hole? If so, do I need a little RTV around the outer edge to help hold it in place, or just dry the surface of the case and install with a driver?

I never thought about RTV but I suppose it wouldn't hurt. When I removed the cover last year the seal just stayed in place.

It seems to hold pretty solid while I was driving it in, until I went too far that is lol. I suppose we'll see how well I do when it comes on tuesday. It's funny, I can perform a number of precise medical procedures under adverse conditions and in stressful situations but in the tranquility of my garage I screw up something so simple! haha.

You could use a 'Seal club'.

The seal goes in from the back. If you'll notice, there's a lip preventing it from coming out. Don't try to install it from the out side. That might be what the PO did. You won't loose much oil. You may be able to save the gasket by tapping on the cover with a rubber mallet. If it does tear, you can use silicon to mend it. No high pressure inside. I use High Temp Copper.
Steve

davido wrote: You could use a 'Seal club'.

:laugh: :laugh: :laugh:
good one

swest wrote: The seal goes in from the back. If you'll notice, there's a lip preventing it from coming out. Don't try to install it from the out side. That might be what the PO did. You won't loose much oil.
Steve

makes sense
Yes, very little oil in there

Awesome, very good info to know that the factory manual leaves out... I will pull the cover and pick up a gasket in case I cannot salvage or cut another one (I have a sheet of gasket paper).

Thank you so much guys!

As for the seal club, well... LOL

Ok I got it, pulling the cover made life so much easier. I'm lucky that there's a vintage Kaw parts place by me, they had both the gasket and seal. Johnny's Vintage Motorcycle in Wadsworth, OH. They said they have every gasket made... so might be a place to check if you're in need of something before resorting to Amazon.

I also ended up replacing the pushrod and shift shaft seals for good measure. I put about 100 miles on it since yesterday and it's good to go.

BTW when you said "you won't lose much oil" well about two quarts came out LOL.

Anyhow, its done and I wanted to thank you guys.