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Counter Sprocket Shaft Seal Replacement


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#1 Desertbound

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Posted 15 March 2005 - 10:51 PM

Steve or Kevin, please move this to the tech section if you feel it belongs there.

Ok, so you are riding and you notice oil spewing all over the rear of your quad. After insection you determine that the oil is coming from behind your counter sprocket. This is a common problem, and so I am going to walk everyone through the replacement of the seal and o-ring.

This is the second seal I have had to replace. I didn't notice the o-ring in the service manual the first time, so the seal was letting oil by again. Here is a step by step of how to replace the seal.

These are the parts you need:

Seal:
Posted Image

O-ring:
Posted Image


1. Drain the oil from your machine. - I did not include pics for this because if you can't change your oil, you shouldn't be doing this seal replacement.

2. Remove your counter sprocket and inspect it.

It should look like this:

Posted Image

The common cause of the seal going out is an object getting lodged behing the sprocket. Many times it will chew up the plastic ring on the back, and that will auger the seal out. Getting your overflow tubes from your carb will also cause this. Here is what happens when something like this happens.

Posted Image

I would suggest going with an aftermarket sprocket to replace the oem. That way you don't have to deal with the plastic anymore. I went with a sprocket specialist.

3. After removing the sprocket loosen the chain and slide the sprocket out. Pull the chain out of your way. I am lucky, I have the 250R adjustment on my swinger:

Posted Image

4. Now you will see the seal that needs replacing. This is what it will look like:

Posted Image

Notice all the grime on my case. That is from the slow leak. That is a sure sign that you are losing some oil through there.

5. Notice the 2 8mm bolts holding a cover over over the seal. Remove the cover:

Posted Image
Notice that I cleaned the area. You don't want the oily sand and dirt crap getting behind the new seal.

6. Now it is time to remove the seal. Screw a small screw into the seal. Not too deep. Just a couple of turns. This will enable you to get leverage and pop the seal out.

Posted Image

7. Now the seal is out. Wipe the area down and make sure it is clean. But where is this o-ring??? I missed this the first time. There is a spacer that needs to be removed. It just slides right off.

Posted Image

Sorry for the blurry pic. There is one side that is beveled. This side goes out.

8. Here is the oring. Grab a o ring pick and get it out of there.

Posted Image

9. Clean the area again and reverse the steps. Make sure the seal lines up with the edge of the case, and be sure to use some moly lube, or white lithium grease to lubricate the seal. Be sure to torque everything back to specs, and you will be riding again in no time.



Total job time....about an hour, and that is taking your time.

Edited by Desertbound, 18 December 2005 - 10:49 AM.


#2 schwendi

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Posted 15 March 2005 - 11:42 PM

Great post! Thanks!!!

Moving to the Tech section

#3 Earnhard3

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Posted 16 March 2005 - 04:34 AM

So if I went to a aftermarket countershaft already I should not have a problem correct?

#4 Desertbound

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Posted 16 March 2005 - 10:07 AM

I'm sure it can leak from other circumstances too, but the stock sprocket is usually what causes it.

#5 Aussiequadrider

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Posted 16 March 2005 - 06:13 PM

Great job mate, thanks.

Geoff.

#6 YFZ450NF150

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Posted 03 November 2005 - 10:27 AM

anyway to update the links for the pictures?

#7 Desertbound

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Posted 18 December 2005 - 10:33 AM

Yeah, I'll do that. Sadly I am changing it again today. I think my case half is screwed up.

#8 banshee_killer

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Posted 21 January 2009 - 11:54 AM

do i need 2 do all that if my sproket isnt leaking and i just want 2 go with a different tooth size????

#9 banshee_killer

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Posted 21 January 2009 - 11:55 AM

do i need 2 do all that if my sproket isnt leaking and i just want 2 go with a different tooth size????

#10 mtxracer36

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Posted 21 January 2009 - 03:03 PM

do i need 2 do all that if my sproket isnt leaking and i just want 2 go with a different tooth size????


no just bend the washer back and remove the sprocket nut

#11 04yfzle

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Posted 21 January 2009 - 03:03 PM

do i need 2 do all that if my sproket isnt leaking and i just want 2 go with a different tooth size????

no just swap it right out

#12 Oregon Duner

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Posted 11 May 2009 - 04:09 PM

Steve or Kevin, please move this to the tech section if you feel it belongs there.

Ok, so you are riding and you notice oil spewing all over the rear of your quad. After insection you determine that the oil is coming from behind your counter sprocket. This is a common problem, and so I am going to walk everyone through the replacement of the seal and o-ring.

This is the second seal I have had to replace. I didn't notice the o-ring in the service manual the first time, so the seal was letting oil by again. Here is a step by step of how to replace the seal.

These are the parts you need:

Seal:
Posted Image

O-ring:
Posted Image


1. Drain the oil from your machine. - I did not include pics for this because if you can't change your oil, you shouldn't be doing this seal replacement.

2. Remove your counter sprocket and inspect it.

It should look like this:

Posted Image

The common cause of the seal going out is an object getting lodged behing the sprocket. Many times it will chew up the plastic ring on the back, and that will auger the seal out. Getting your overflow tubes from your carb will also cause this. Here is what happens when something like this happens.

Posted Image

I would suggest going with an aftermarket sprocket to replace the oem. That way you don't have to deal with the plastic anymore. I went with a sprocket specialist.

3. After removing the sprocket loosen the chain and slide the sprocket out. Pull the chain out of your way. I am lucky, I have the 250R adjustment on my swinger:

Posted Image

4. Now you will see the seal that needs replacing. This is what it will look like:

Posted Image

Notice all the grime on my case. That is from the slow leak. That is a sure sign that you are losing some oil through there.

5. Notice the 2 8mm bolts holding a cover over over the seal. Remove the cover:

Posted Image
Notice that I cleaned the area. You don't want the oily sand and dirt crap getting behind the new seal.

6. Now it is time to remove the seal. Screw a small screw into the seal. Not too deep. Just a couple of turns. This will enable you to get leverage and pop the seal out.

Posted Image

7. Now the seal is out. Wipe the area down and make sure it is clean. But where is this o-ring??? I missed this the first time. There is a spacer that needs to be removed. It just slides right off.

Posted Image

Sorry for the blurry pic. There is one side that is beveled. This side goes out.

8. Here is the oring. Grab a o ring pick and get it out of there.

Posted Image

9. Clean the area again and reverse the steps. Make sure the seal lines up with the edge of the case, and be sure to use some moly lube, or white lithium grease to lubricate the seal. Be sure to torque everything back to specs, and you will be riding again in no time.



Total job time....about an hour, and that is taking your time.


ok so the spacer that goes in there, you said goes beveled side out?? which side do you consider the beveled side? The flat sode that has the outer lip reamed, or the side that has the little half circle things cut all around the spacer?




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