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