How to replace outer crankshaft seals on T500?

CaptCatFish

Somwhere on this Forum, I remember someone stating that the outer crankshaft seals can be replaced w/o removing the engine/splitting the cases.

I think I need to do this because the right side of my T500 is smoking a lot more than left side and has a distinctive sound difference through the exhaust. I suspect the seal is allowing transmission oil past it into the crankshaft compression area, hence the excessive smoking on that side.

Any advice or insight about how to do this would be greatly appreciated.

Thanks!

CaptCatFish

Bikegeezer

CaptCatFish · Posted: Thu Jun 10, 2010 5:34 pm Post subject:

Thank you Bikegeezer!

I've got the clutch cover off and the clutch plates removed. However I am puzzled as to how to remove the inner clutch basket nut (a 1 1/4" socket fits it) and the primary nut (also a 1 1/4" socket). Are they both right-threaded? Or is the one on the inner clutch basket left threaded?

Any tips on how to remove them (I don't have any air tools) would be greatly appreciated.

CaptCatFish (Jim)

zjeppe · Posted: Thu Jun 10, 2010 10:10 pm Post subject:

Allas, airimpact gun is definitly the way to go Rolling Eyes

CaptCatFish · Posted: Fri Jun 11, 2010 1:24 am Post subject:

I've always wanted a really good compressor and air impact tools. Unfortunately, its a long time until my birthday (and the next few after that) so it looks like I'm going to have to figure out how to jam the clutch basket and primary gear to loosen those nuts. That is of course, as soon as I can find out whether or not they are left or right threaded.

Thanks in advance to anybody who wants to weigh in on this.!

Jim

Russell · Posted: Fri Jun 11, 2010 2:50 am Post subject:

I have seen a little tool made from a single piece of metal sheet bent and folded in certain ways that can be used to safely jam the primary drive mechanism so that you can put a big bar on the socket on that centre nut-sorry I cannot recall where I saw it.
If the motor is out of the bike it's worth just carrying it to some-one with a 'rattler'. The nut,which memory(a long time ago) says was a conventional right hand thread,shifts easily with the 'rattler'.You could take it to a tyre fitter...so long as you have the correct sockets. Most here wouldn't charge anything for a 20 second job like that.

CaptCatFish · Posted: Fri Jun 11, 2010 4:26 am Post subject:

Thanks Russell!

I've got a hand impact tool that will work (under most circumstances) but have access to a shop with air tools (if worse comes to worse). I was able to get the generator hub off of the left side without consequence and see how to get to the left side seal after the circlip is removed.

I'm fortunate in that I have a donor T500 motor to practice my skills on before I attempt this surgery on my primary T500 ride. However, I don't want to tear anything up on the donor motor for obvious reasons.

Jim (aka: CaptCatFish)

sesshomaru · Posted: Fri Jun 11, 2010 9:23 am Post subject:

When I tore down my RD motors, I took a folded up rag and jammed it in between the primary drive gear and clutch. A penny works as well. Make sure you use a breaker bar when you do this...makes things a lot easier. Also, it helps if the motor is still in the frame while you do this.

CaptCatFish · Posted: Fri Jun 11, 2010 10:42 am Post subject:

Thanks Everybody!

I got the clutch basket off (it is right-threaded and loosens the conventional way) by bolting a metal holding strap between one of the inner clutch basket posts and the outer casing.

Now the problem is loosening the large nut that holds the primary gear to the crankshaft. For the life of me, I can't tell if its right threaded or left threaded. I've banged on it both ways with my impact driver and a big hammer but can't get any movement either way to speak of. I'm a little afraid to hold the bolt on the other side (that goes through the stator) out of concern that I'll strip it out.

Any ideas?

Thanks in advance and best regards to all.

Jim

Russell · Posted: Fri Jun 11, 2010 1:05 pm Post subject:

Jim...can't help as to direction of thread but why not fit up loosely the clutch hub again , locking it in the same way as previously, and then undo your crank nut?

CaptCatFish · Posted: Fri Jun 11, 2010 6:51 pm Post subject:

Good idea. I'll try it tomorrow (or asap) and post my results. Your suggestion sounds more logical than chasing the crankshaft nut around this way then that without any way to lock it down to see what really works.

Later (and thanks again)

Jim

Bikegeezer · Posted: Tue Jun 15, 2010 11:46 am Post subject:

CaptCatFish · Posted: Tue Jun 15, 2010 4:57 pm Post subject:

Thanks Stu,

Now I've got to go ahead and order the seals for both sides. I could be loosing my mind but I think I remember reading that the right crank seal is no longer available through US parts people. .

Know anything about this? If true, have any idea where I might find that seal or a set for both sides?

Thanks for your help. I really appreciate it.

Jim

Russell · Posted: Tue Jun 15, 2010 5:13 pm Post subject:

Try this outfit. They have an incredible amount of NOS Suzuki stuff and freight across the Pacific can be just as quick as across the USA.

http://www.suziparts.com.au/

Bikegeezer · Posted: Tue Jun 15, 2010 6:04 pm Post subject: