Gpz550- found faulty seals- help!

i found at least one major cause of the oil leak in my 94 Gpz. I was hoping someone could clarify this for me. Right behind the front sprocket I found a rubber seal that was totally corroded and halfway gone. See picture one. I'm not sure if this is the shift shaft seal. After pulling it out, behind it I found a much more rigid seal or bearing, can't tell yet, that's intact but not seated properly. I'm thinking this is the actual shift shaft seal. You can see in picture two how it's about 5 mm too high up.
Any thoughts moving forward? As always, thanks for the help.

Need a larger view. Is this a shaft drive?
Steve

I think that's the output shaft. There is an oil seal that fits into the mission cover to protect the bearing.
Partzilla. 1984 ZX550 Breather-cover/Oil-pan diagram. 92050-024 --- OIL SEAL --- SC325210
The seal may be available at the Kawasaki dealer.

Without using a solvent or using a clean cloth just dampened w silicone spray lubricant, I guess I would wipe off the crud as best I can without contaminating the bearing, then install a new seal. If necessary, I guess I would pack the bearing w some more grease. ???

Ride the bike & check for a leak. Keep in mind that the front sprocket area can get pretty grungy from chain sling,
so there may not be an oil leak.

It's a GPZ model not a shaft. I get it. There is no grease in there. :whistle: The cover comes off and the seal goes in from the inside. I'd check the bearing while in there, if good replace the seal and go for it. :woohoo:
Steve

Steve,
So is the seal the black rubber o-right type that was broken in the first picture, or the flat, more rigid ring in behind it in the second picture?
Thanks so much!
Joe

O-ring*

Maybe have a read through here on the JIS cross head fastener bits, the oil seal cover fasteners can be tight and if they get damaged it is more aggro removing them.

Whilst you are there, get a new gasket and other oil seals: one for the gearshifter 92049A on the transmission plate under the drive sprocket, and if yours is an earlier model with pushrod clutch, get an oil seal for that too.




GPz550 series ran until 1989, your bike maybe one that got left on the shelf and registered late or imported. It would be handy if you can quote exactly what model it is.


PS There is another oil seal, the same as used on the gearshifter that goes in the engine outer casing gear shifter hole. Bit of a misuse of an oil seal as there is very little oil there, just supports the gear shifter and gives for smoother shifts. I can't even find it on parts diagrams but did it on mine only last month.
parts diagrams

Okay, I've ordered all three seals in that diagram. Hopefully I'll get somewhere once I get them. Thanks all.
Joe

Get yourself a hand impact driver. It will remove the screws and reset them with a couple taps. Must have for bikes.
Steve

Weird looking bearing. Partzilla has a photo of the output shaft bearing & there are several of them listed on eebbaayy. I've never seen anything like it --- not sure what the black thing is --- it doesn't look like a rubber shield. :blush:

92045-035

92045-035

It is a hardened cage. Looks by the bevel there's a small O ring that goes between the collar and the gear inside like the Z1. If not disturbed and the bearing is OK, a new seal 92049 should take care of it.
Steve

Good point Martin, never noticed that.

OP just hope it is the oil seal stuffed - although usually they look fine but leak. Hopefully it isn't your output shaft bearing collapsed taking the oil seal with it. Check that carefully, it is one of the most highly stressed bearings on the whole bike.

Definitely use an impact driver on the inner casing JIS fasteners, but avoid air impact tools on the output shaft, the bearings don't like it like it.