Alan

The little spring behind the seal lip can be removed, separated, shortened and rejoined. You'll see the join in the spring ring. Grab both sides and turn the right side counter clockwise. It should seperate. Cut a little off the larger end then rejoin. This will put a little more pressure on the seal lip to shaft.

BLUDGEONER

Is the KTM 65 seal oversize - 5mm/6mm, or same as standard 10x18x4? I'm going to have one more shot at the seal (+ the BBSKF6201 bearing) before I take the engine to bits completely. I'd like to try an oversize/thicker seal just to eliminate the worn shaft scenario.
Cheers.

bushmechanic

It's the same size but It seems to work better than others when the shaft is worn

Wolfy

Went through many iterations of changing the seals.

The Kawasaki seal does not work.

The blue KTM seal works the best. You will need 10mm diameter heat shrink piece that will shrink down to 5mm. I used Emory cloth to clean up the grooves. The heat shrink is the key. I ended up replacing the seal (7) times before I got everything to seal and work correctly; mostly because the kick start shaft kept coming out when I pulled the cover, then forgot to check it before reassembly. I keep a few spare seals around and replace them whenever I go into the clutch side. I now have over 2000+ miles on the last seal.