Maintenance & Technical > KX500 Original

Crank seal Replacement question

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Rick:
I have not yet torn into the bottom end of my 2002 KX500, but think I have the wet side crank seal leaking oil into the engine.   Here's my question:  Can the wet side seal be changed without splitting the cases on a 2002 KX500?  

I know the newer KX250 cranks seal must be installed from the engine side, as there is a lip on the transmission side of the seal pocket that keeps you from driving the seal in from the transmission side.  However, since I have not taken my 2002 KX500 apart yet, I'm not sure if the seal pocket has a lip on the newer KX500's.  Anyone taken a 2002 apart yet to know about the seal pocket?

Manny, if no one has pulled a newer bike apart, can you check with John B. and see if the wet and dry seals can be changed on a 2002 KX500 without splitting the cases.

Thanks guys.

Rick

kawdude:
My 94 cannot be changed without splitting the case.  If you look on the kaw website the diagrams don't look any different.

Pinchy:
I got my 500 tore apart and the case split and the crank decided it wanted to stay in the Right Half of the case.
I took the clutch basket out of the way so I could heat the case up around the bearing. Didnt have much luck , maybe i didnt get it hot enuf but I got tyred of wasting propane and dont really feel like cranking up my acetyl
torch;) and I really dont want to bugger up the end of the shaft anymore.

Is it normally taken out with a press? I figure the next step would be take the rest of the tranny out and put it in a friends press.

And what are some good tips to removing the end bearings once its out?
Im leaning toward the caveman chisel approach myself. If i remember they had bearing pullers that looked like a guillotine sorta with 2 halves with the center sharpened to dig in behind the bearing but i bet youd run into problems coz the crank would be in the way of tool since it has such a large diameter.

kawdude:
Go to harborfreight online and order that bearing puller.  Normally its a .0005" press fit into the bearings and you won't be able to pull it off without it.  You may be able to heat the inner race enough to get it to pull without one.  Either way use heat.  I also believe you may need to pull the left case off first using a puller that pushes on the crank and pulls on the stator bolt holes.  Do a search on "rebuilding".  You should find a lot of info.

DanH1:
Be patient, take your time and buy, borrow, or rent the correct pullers! It will save you many headaches and $$. Remember the speed that the crank turns, so you really don't want to pound on it too much, and easy on the heat. In the long run you will be $$ and performance ahead.  


                                                                             Dan

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