Replace shifter seal on Z440 ltd

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I've got a belt-drive 83/84 KZ440 ltd.
It's leaking oil out of the hole where the shaft from the gearchange lever goes in (just below the engine drivebelt pulley).
I've bought what I believe is the correct seal, but it looks like the only way to install it is to split the cases and go at it from the back? Please tell me I'm wrong, but I can't see how the seal can fit in any other way. Any ideas?
This is the part I bought:

Thanks,
Dan

I'm not familiar with the 440 & you can see what you've got better than I can, but from the diagrams it seems to me that the seal is pressed in from outside of the crankcase. I can't imagine that you'd have to split the cases to replace that seal.

Did you try sliding the seal over the shifter shaft for comparison?
It's within the realm of possibility that the wrong seal was sent.

Are you absolutely sure that is where the leak is? Have you removed the sift lever and the chain cover and cleaned the area to confirm?
The reason I ask is that sometimes newbies mistake oozing chain lube for a leaky seal. If it is the shift shaft seal, then a small, pointy, hooked tool should do thr trick. Clean the shaft and the area where the new seal will go very well. Put a little oil around the inside of the seal so it will slide easily along the shaft. Be very careful so as to not damage the new seal. A small diameter wood dowel can be used to carefully tap it home. Tap gently all around the seal so it will not go in crooked.
Before doing this, though, the most important tool you need is a genuine factory service manual. It will save you far more than its cost.

I could be wrong, but that seal might be difficult to remove for a first timer.
I would spray it with a penetrant beforehand & let it sit overnight or longer, then have at it.
Search the internet or youtube for how to remove a shifter seal or search shift shaft seal leak or something like that.

Changing your shift shaft seal on most Suzuki Twins

Left hand shift shaft seal replacement on the Kawasaki 2 stroke triples --- good video
note: milk jug plastic is good for protecting stuff when levering against metal parts.
not always practical, though. might be hard to use in this case.

It looks like there's a cover like the rest of the KZ/Z1's. Don't try to install it from the out side if there is. I'd buy all the seals being they are so cheap.
www.google.com/imgres?imgurl=http://i138..._gkcYCFdUviAod0u8CLw
Steve

martin_csr wrote: I'm not familiar with the 440 & you can see what you've got better than I can, but from the diagrams it seems to me that the seal is pressed in from outside of the crankcase. I can't imagine that you'd have to split the cases to replace that seal.

Did you try sliding the seal over the shifter shaft for comparison?
It's within the realm of possibility that the wrong seal was sent.

+1

You can find a manual for the 440 at www.400.com . Also lots of technical tips.
From a brief look I dont see that the 440 has a transmission cover like the larger bikes. If you can take a photo of the area it would help.

I also have a dim memory that someone with the same problem made a simple repair by sliding a seal with larger outer diameter over the gearchange shaft and gluing it in place ...... after cleaning well first.

Good luck

From what I could see it does have a transmission cover. My CL 350 Honda didn't have one so I had to pry out the old one and drive in the new one. Didn't last very long. Lets hope he has a cover. The seals go in from the inside. There is a lip that holds them in. Trying to drive in a new one will damage the rubber and not be tight. Also there was talk about the 750 twins having the same seals but different part numbers.
Steve

I think you're looking at the stuff from 750-Twin which has a mission cover.
The 440 is different & doesn't have a transmission cover.

Hello and thanks for all your help everyone. I think whoever said the seal may be wrong was correct. Unfortunately I also think it has to go in from "behind". I'm going to try and sort something for the short term.



Thanks again!

is that what it looks like right now?

Have you taken off the front pulley/sprocket to see if oil is coming from somewhere else and dripping down on the shifter and at the end of the day Is it really worth splitting the cases for that ?