I guess this might be why I can't find it on the internet... Either way, I have a plan and I'll post the results when completed.
Countershaft seal replacement
Has anyone out there had the pleasure of changing one of these seals? I've done them on dirt bikes before and have started in on my '02 919... I'm buying my second new seal tonight, not happy. The old one did not want to come out at all! I made it come out though. Now, does anyone have any tricks to get a new one in smoothly? I just bent one tonight and had to toss it. What did you use to install it? Or did I get myself into a situation where I was suppose to split the case? I did some searching around and I didn't really find much on this issue with Honda sport bikes. The manual doesn't touch this issue either that I can see.
part number info: 91207-MW0-003
part number info: 91207-MW0-003
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I am interested to know. I have seen it done on other bikes, but those were obviously not retained.
Isn't that a deal with a lip on the back? I replaced mine, but my cases were apart.
You need a driver that spans all the way to the outer edge of the seal.
I've used deep sockets to drive in seals before, but non as big as your countershaft seal.
Know any mechanics?
I've used deep sockets to drive in seals before, but non as big as your countershaft seal.
Know any mechanics?
Looking at the IPB, it definitely looks to be a lipped seal. So the cases come apart:-(
Yep, I found that out after I had pulled the old one. Which is why it took almost an hour of careful work to get it out. I should have looked into this before I started. I didn't open the new one first either to check it. I was just going off prior knowledge of other bikes. I'm still waiting on the next one, if I can get it in I'll post the results. If not, I'll be engine shopping. This one is a salvage bike project anyway and was just trying to get it going quick. There is other damage to the engine as well, but it ran good. Anyone have an engine they need to unload?
It's not terribly hard, just intimidating to do. Drop the motor, flip it upside down, and pay attention to what goes where. Make sure you re-torque things properly and use a tiny bit of quality sealant on the exterior mating faces of the cases, and take your time.
This sounds like the situation when I was working on RD 350 / 400's -- the countershaft seal had a lip inside that did not prevent removing it, but made it impossible to install the new one. What we ended up doing was to find a suitable seal with the same ID and OD, but without a lip. In the case of the 919, the dimensions are 62mm OD and 40mm ID, a common size. As long as it is thinner than 8.4mm you' re good.
Rob
Rob
You've got my attention. Where would I shop for said seal? Honda shop?This sounds like the situation when I was working on RD 350 / 400's -- the countershaft seal had a lip inside that did not prevent removing it, but made it impossible to install the new one. What we ended up doing was to find a suitable seal with the same ID and OD, but without a lip. In the case of the 919, the dimensions are 62mm OD and 40mm ID, a common size. As long as it is thinner than 8.4mm you' re good.
Rob
https://www.google.com/search?q=62m...rome..69i57.1447j0j7&sourceid=chrome&ie=UTF-8You've got my attention. Where would I shop for said seal? Honda shop?
I answered my own question regarding the alternative seal. I've been using All Balls Racing seals for many thing in the past, and low and behold they have a seal that (I think) meets the needs. p/n: 30-6205. It's only 7mm thick, but I ordered it anyway, it was half the cost of the Honda seal, which is on order too. I'll try the All Balls and hope to hell it doesn't leak. We will see.
Update: The all balls seal fits nice and is holding oil...at least so far. I used a PVC coupler on the end of a short piece of 1.5 inch pvc pipe. The couplers have a nice smooth edge and is wider than the pipe. It made good contact when hitting it with a hammer, slid right in with it oiled up.
Awesome, I appreciate the update. I will be saving this for future reference!
Bringing this one back from the dead! I've got an 02 919 with 55k miles and a pretty bad countershaft seal leak. I put it off last season and just left a little oil spot behind each time it was parked lol.
But thank you so much runaway919 for the info! Any feedback on how it held up over the long term? I ordered one of the all balls 30-6205 and should be getting it in next week, I'll be sure to report back.
But thank you so much runaway919 for the info! Any feedback on how it held up over the long term? I ordered one of the all balls 30-6205 and should be getting it in next week, I'll be sure to report back.
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