Harold Bawlzangya Racing

Case modification – replace crank seals without splitting the cases

Better way HERE.


 

I’ve been researching this for a while and finally took the plunge.  Yamaha and Honda allow you to replace the crank seals without splitting the cases.  But these lips that Kawasaki manufactured into the cases prevents that.

Partial lip on flywheel side:

Cases - crank seal removal (10)

(click picture to enlarge)

Cases - crank seal removal (4)

(click picture to enlarge)

Full lip on clutch side:

Cases - crank seal removal (2)

(click picture to enlarge)

Cases - crank seal removal (3)

(click picture to enlarge)

 

Honda doesn’t use a retainer on either crank seal:

http://www.allthingsmoto.com/forums/f-235/round-three-92-01-cr250-engine-build-46010/

 

And Yamaha only uses a retainer on the clutch side (~5:20).   At about 5:46 of this video, he just pushes the crank seal in with his fingers.  I can’t tell from any of the 3 RMATV videos, but the stator could serve as a seal retainer.  But I did notice that the seals Yamaha uses are different than what the KDX uses.  No way are you installing the KDX seals with just your fingers.

 

The more I’ve thought about it, I’m thinking those “lips” are more of stops that put the crank seal in the correct location.  If there was concern about the seals moving and popping out, I would think there would be an equal concern with the seals moving inwards and blocking off the oil passage.  I’ve yet to see a seal that wasn’t seated against the lip, so I highly doubt that they move.

So here we go . . .

Flywheel side removed:

Cases - crank seal removal (12)

(click picture to enlarge)

Clutch side removed:

Cases - crank seal removal (15)

(click picture to enlarge)

 

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