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I have an oil leak on my bike where the countershaft sproket goes. I replaced the seal and it still leaks the same amount if not more. It is a bad leak, not just a few drops. Any ideas on exactly what parts need replaced besides the seal itself?

Paul
Parker, CO
 

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Discussion Starter #2
Oil Leak

I replaced my counter sprocket seal for the second time. Originally the leak was really bad. After I replaced the seal the first time the leak was really, really bad.

This is the second time I replaced it. I cleaned the seal, the shaft, and the casing where the seal seats. This time I put a little light coating of RTV black around the seal in an attempt to help.

I am trying to find out if an oil leak from this area is a known problem. If it doesn't get fixed this time I will go ape sh!t. I also replaced the o-ring, and lubed the seal with a light coat of oil.

Thoughts?

Paul
Parker, CO
 

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counter sprocket seal leak

I have a 250 exc., IM so glad im not the only one that the countershaft sporocket seal leaks.It started out ,a slow leak.the seal look good.I carefully removed everything, Cleaned the shaft with wd40,Lightly greased shaft and seal,It still leaked.Now I've put a new seal on,and now,it leaks worse.It SUCKS! I have no idea what to do now.And its all over a simple countersprocket seal getting replaced.Ive done topends,a little in total engine teardowns,and I know my way around a motorcycle.But this leak is about to drive me crazy.Would having too much oil in crankcase cause this?
 

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Discussion Starter #4
Oil Leak

I put RTV black around the perimiter of the seal. That seemed to do the trick. That was the second time I replaced my seal. When I replaced it the first time I made it worse somehow.
 

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2007 525exc countershaft oil leak

I have an oil leak on my bike where the countershaft sproket goes. I replaced the seal and it still leaks the same amount if not more. It is a bad leak, not just a few drops. Any ideas on exactly what parts need replaced besides the seal itself?

Paul
Parker, CO
I am having the same problem with my 2007 525exc. I have replaced the shaft seal and the leak has slowed, but has not stopped.

Like paul, I would like to know if there is another solution for this leak.

Thanks,

WhiteCa
 

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I have an oil leak on my bike where the countershaft sproket goes. I replaced the seal and it still leaks the same amount if not more. It is a bad leak, not just a few drops. Any ideas on exactly what parts need replaced besides the seal itself?

Paul
Parker, CO
Paul,
The only ways oil can get out, is too small a shaft, or too big a seal.
Check the shaft for a groove. if found replace.
Check local parts houses or industrial suppliers for a smaller seal.
Sometimes an american (sae) seal is just enough smaller than it's metric counterpart that it will work.
mike
buena vista, colo
 

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Having just alittle too much oil in crankcase would cause it to leak.Also,a aftermarket front sprocket is thinner than factory,which would not make a good seal against the oil ring.I had renthal front sprocket ,I could move in and out ,oil would look like it was coming out of the c-clip.I put a KTM sprocket, no oil leak,and Icould not move it left or right anymore.
 

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Discussion Starter #8
oil leak

Got it fixed. I took it into a shop, not sure what trick they did to get it to stop.

Paul
Parker, CO
 

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just went through this ..KTM says to reseal ignition case with jb weld ..apply on engine side only ..for future removel.i went through 3 seals before i found out where the leak was coming from.the ignition side has oil in to ..just a new gasket wont help..if you can find one anyway.i did what they said and now ive got a nice clean engine again.
 

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Clean the area with degreaser. Check your oil levels, and take it for a ride. When you get home play detective. Let it run out and get down there with a flashlight and find out exactly where it’s coming from. Hope you didn’t crack the case when the chain broke. Might just be the seal for the clutch slave. Could be be the seal behind the front sprocket. If it’s really had to figure where it’s coming from, you can clean, dry, and then spray with some of that foot powder you have lying around in the medicine chest. It comes out white, and the oil will leave a trail through it.
 

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I have a 2007 525 xc and have same problem, i even replaced the bushing for 35 bucks and hoped it stoped the the leak, i'm going to try the factory sprocket first because i have the play in and out of the case, i'll check if it goes away. i don't know about putting jb weld on it, if it its small gap or uneven rtv should had been enough.
 

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I have replaced- the seal, o ring, and the spacer but oil still leaks, i noticed that the inside ring of the countershaft bearing can spin freely on the shaft, so oil must pass through there and leaks through the splines and comes out of the outside of the sprocket, Has anyone had this problem before? to fix it properly would i have to split the cases and replace the shaft and bearing? thanks in advance
 

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2007 KTM 525 EXC Countershaft Oil Leak

Hey Guys,

I had the same problem with my countershaft leaking oil when I rode the bike. (It did not leak when the bike was off.) It took me a few weeks to finally fix it.

After many trials and errors I finally fixed it by replacing the CS O-Ring, CS seal, CS metal bushing, replaced aftermarket CS sprocket with OEM sprocket, CS washer and bolt. (All parts were OEM KTM parts.) I don't believe you need to replace all of these parts but it doesn't hurt if they are older or the original ones. They are not that expensive. (The most important to replace are the CS seal, metal bushing and OEM sprocket.)

My theory is that the aftermarket sprocket was too loose on the countershaft due to its teeth being slightly smaller than the OEM sprocket teeth that hug the CS. This extra vibration over time weakened the bushing and seal causing space to develop between the rubber seal and the metal bushing. My bushing even had visible lines worn into it from where the seal was touching it.

(I also think that a loose chain can provide too much vibration on your CS sprocket, leading to the same issue. So keep you chains at proper tension.)

When you take the sprocket off and look closely where the CS seal meets the metal bushing, there should be no space. The seal should hug the bushing tight. If there is ANY space, this is where oil can come out.

To remove the old CS seal, (these are usually stubborn) use a small allen wrench to pry it out by hooking the short end of the wrench under the metal part of the seal and the long part leveraged against the outside of the metal part of the seal.

Make sure when you install the new CS seal, that you do not bend it in any way or tear the rubber seal. If you do, it will be compromised. Install the seal as gently as you can by tapping a blunt hammer or using a hammer and towel to soften the blow to the seal. When you install the new metal bushing, make sure you slide it gently inside the rubber seal so that the seal hugs the side of the metal bushing evenly. Do not let one part of the rubber piece bend under itself. The seal should be snug to the bushing. (This is the most important part.)

I even , with my finger, gently pushed the rubber part of the seal inward toward the CS before I slid the bushing on to make sure that it was going to be snug against the bushing. If you do this, do NOT push hard or you could compromise the seal integrity.

I hope this works for you! I was super frustrated with this leak for a long time and I promised that if I ever fixed it, I would post this on every forum that I previously visited.
 
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