KTM countershaft seal – help needed

[Luke CharlesworthMember]

Hi all

I noticed oil on the shed floor under the ktm 300.
I traced the leak back to the countershaft seal. I have replaced the o-ring, shaft seal ring, spacer and put a new KTM OEM sprocket on and it is still leaking oil :angry: . I have not ridden it since the new seal was put in, only started it to warm up and left it over night. The chain is not over tight. Bike had around 5500km before bottom end rebuild last month and new 300 cylinder kit put on last week.

Any ideas?

Cheers

[Matt BakerMember]

When grit gets caught between the shaft and seal it wears a tiny groove in the shaft, either push the seal a bit further in or pull it a bit further out so its not sitting in the exact same groove. Then just make sure you don’t over tighten the chain.

[AlexMember]

Wrong size O-Ring. Depending on how dodgy your dealer is they either give you the correct sized one (KTM) or something from the local bearing shop that is the wrong size/dimension.

[Luke CharlesworthMember]

Thanks LC4skin. I had replaced the o-ring, new shaft seal ring and new spacer sleeve last night. So everything is new which is why I didn’t expect to see oil on the floor this morning. The old spacer sleeve I pulled had the tiny groove marks you mention hence I though replace the lot and I should be fine.
Cheers

[Luke CharlesworthMember]

Cheers Axel. I didn’t measure the o-ring before popping it in. Will do tonight. May even try a slightly thicker one maybe??

[murph the surfMember]

I have replaced quite a few of these over the years.
Sounds like you’ve done the right thing by replacing the three items.
Just be carefull when fitting the spacer that the thin O-ring seats where it should.
From memory (which is not as good as it used to be) I used a thin film of O-ring grease on the O-ring
Other than that I have nothing
Might be worth another look
Good luck
Cheers
Murph

[AlexMember]

Luke Charlesworth wrote:

Cheers Axel. I didn’t measure the o-ring before popping it in. Will do tonight. May even try a slightly thicker one maybe??

I only say this because a mate did exactly the same – replaced the lot (good idea). Found oil in the morning. Put the new O-ring up against the old one and they were not the same thickness/size. Ordered one from Boltons and it came in a KTM part labelled bag – correct size = no leak.

[andrewMember]

LUKE my friend I know this will get deleted

I can only say..

SHERCO my friend SHERCO

it will solve all your problems with the KTM..

MODS this is serious TECH HELP I promise

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