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.

BLUDGEONER

Thank you. I will give this one more go when time allows...

Taffy

I just don't have any trouble.

If i think I'm going to have a problem I use an extra thick gasket and shunt the whole lot out.

copper washers behind the sledge plate
thick sidecover gasket
press the original seal in but leave the lip 0.5mm proud. there is often a machined recess in the bottom of the W/P housing. I have a piece of bar that presses seals down until level with the unmachined area and is therefore 0.5mm proud.

put the gasket and the seal together along with a new polyamide (most times) and I'm sure not to be pulling the cover again.

I once used the KTM65 seal and it fell in the hole so i shook the cover upside down and it fell out again!

http://taffmeisters.co.uk/product_in...oducts_id=2319

or

http://taffmeisters.co.uk/product_in...oducts_id=2394

regards

Taffy