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post #1 of 15 (permalink) Old 07-15-2010, 01:17 PM Thread Starter
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minor problem

I'm trying to remove the output shaft sleeve on my 900 Sprint to replace the oil seal. The sleeve will spin on the shaft but I can't seem to pull it off and I don't see a circlip holding it. I checked out N5XL's excellent write up on this but he just mentions removing the sleeve. Am I missing something or just not pulling hard enough?

If the force is with me, will it be easier to get my bike onto its centrestand?
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post #2 of 15 (permalink) Old 07-15-2010, 01:42 PM
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Just looked at the bikebandit parts breakdown - doesn't appear to be anything holding it - anyone else?
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post #3 of 15 (permalink) Old 07-15-2010, 02:30 PM
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Sorry, I'm clue-free on this one.

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-Kit
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post #4 of 15 (permalink) Old 07-15-2010, 03:29 PM
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I couldn't get mine off either...just double checked the factory manual and there is nothing holding it on....mine didn't rotate on the shaft it rotated with the shaft :-/ I'm sure with a good enough tug it would have come off but it's not the easiest of things to get hold of !!!!!

I carefully destroyed the oil seal to remove it and replaced it straight over the spacer...be carefull not to mark the shaft if you do take this route as the lips of the seal will need to run on it to create a seal ;-)

It would only take a little crud/corrosion to stick the thing on quite well all the more so for it having been on there for the last 15 years :-0

Maybe NX5L will be able to offer so crowbar free advice ! ;-)

All the best with it
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post #5 of 15 (permalink) Old 07-15-2010, 04:43 PM Thread Starter
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Oh come now Mot...what kind of bozo would use a crowbar to work on a motorcycle...I mean really!

By the way, does anyone know the purpose of that sleeve? I mean other than to hold in the oil seal? What happens if I scratch that in taking out the seal Mot's way? Can a slight scratch be sanded out or is a new sleeve in order? I know this is a pessimistic point of view, but given my luck lately(all bad!), I may as well be prpepared!

If the force is with me, will it be easier to get my bike onto its centrestand?
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post #6 of 15 (permalink) Old 07-15-2010, 07:30 PM
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Quote:
Originally Posted by darthandy View Post
Oh come now Mot...what kind of bozo would use a crowbar to work on a motorcycle...I mean really!

By the way, does anyone know the purpose of that sleeve? I mean other than to hold in the oil seal? What happens if I scratch that in taking out the seal Mot's way? Can a slight scratch be sanded out or is a new sleeve in order? I know this is a pessimistic point of view, but given my luck lately(all bad!), I may as well be prpepared!
I scratched mine...lightly mind and all the time I was awear that a really bad cock up at this stage might mean eangine dismantling to fix !!!! I rubbed it out with some 1500 grade wet and dry and kept the area V clean..

All oil tight for the last few hundred miles so far.....
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post #7 of 15 (permalink) Old 07-16-2010, 12:08 AM
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Andy,

I wish I could offer up some helpful advice on what I did to remove the sleeve, but it literally come off with nothing more than finger pressure. I simply grabbed it with my fingers and it came straight off. Based on Mot's experience, it is starting to sound like I might have been the odd man out. I assure you I had absolutely no difficulty removing it and there is no other fastener holding it in.

To Mot's point, I could easily see some rust or general debris getting in there and causing it to be difficult to remove. No fear if its stuck...it should be very easy to remove the seal without removing the sleeve. If it wont budge, simply leave it alone. There are a couple of ways you can work around the problem.

1. Use a small, flat bladed screwdriver (the smaller the better) and use it to "punch" a hole in the face of the existing seal. Gently hammer it into the flat face part of the seal...about halfway between the sleeve and where the seal fits into the bore of the crankcase. Once you punch a hole in the seal, you can use a screwdriver and lever out the seal...better if you use a seal puller like I have pictured in the writeup. The 90 degree bend in the seal puller is what you want to rest on the edge of the crankcase and lever the seal out.

2. Use a short, self tapping screw and screw it into the face of the seal. Once it starts, you dont want to screw it in too deeply for fear of damaging the bearings underneath the seal. About 1/4 inch is as deep as you want to go. Once the screw is in, use a screwdriver and lever against it to pull the seal out.

3. If neither of the above are working and you are simply tearing the seal apart, continue to pull at the seal body using needle nose pliers and you'll likely find that the seal will come out...I've removed many seals this way, thinking I was going to have to cut the seal body out with a dremel tool.

In all of this, be mindful of the sleeve. Its OD is the surface that the seal is riding on. If you deeply gouge it, you'll have to replace it but if you simply scratch it, you can remove the scratch with a fine grade of sandpaper. Use 220 to get out deeper scratches, then move up to say a 400 and finish off with some really fine stuff like 1500. Carefully done and taking your time, you wont have a problem.

Dave - 1998 Sprint Executive

Last edited by N5XL; 07-16-2010 at 12:10 AM.
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post #8 of 15 (permalink) Old 07-16-2010, 09:36 AM Thread Starter
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Thanks N5XL (May I call you "N"?) I appreciate the info. I was out last night again heaving merrily away at the sleeve (by hand) and the best I was able to do was to get it to a point where it no longer spun on the shaft. It looks like one of your other methods will be required. By the way, does that sleeve extend "into" the seal? I somehow don't see the seal riding on the visible part of the sleeve as it presently sits. Or does the seal slide forward when in use? Just curiious.

And thanks again.

If the force is with me, will it be easier to get my bike onto its centrestand?

Last edited by darthandy; 07-16-2010 at 09:37 AM. Reason: added a bit
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post #9 of 15 (permalink) Old 07-16-2010, 10:57 AM
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Please feel free to call me Dave (as listed in my signature), or call me anything you like...just dont call me late for dinner (as the joke goes)!

If you take a close look at the sleeve, you can see there is a polished looking area and dull, rusty looking area. The brown line in between the dull and polished area of the sleeve is where the seal actually rides.



The sleeve is simply a steel cylinder that is slightly beveled on the inside facing ID and beveled on the outer facing ID and OD. The bevel on the inner facing part of the sleeve mates (agrees with) with a machined area on the sprocket shaft (just behind the "toothed" part of the sprocket shaft in the photo).

You can see from the photo that the seal only "rides" on the inner most few mm's of the sleeve surface...the remainder of the sleeve is for keeping the countershaft sprocket in alignment with the rear sprocket so you dont wear out your chain.

Once you get your seal out, look carefully at the sleeve. Clean it up with a rag and some carb cleaner...you want it smooth with no rough places. If you scratched the sleeve when you removed the seal, use some fine wet/dry sandpaper to remove the scratches.

In your case, your replacement seal will slip over the sleeve with the sleeve still in place. Oil the ID of the new seal with engine oil and press the seal home, over the sleeve so that its flush with the engine casing and not any deeper.

Dave - 1998 Sprint Executive
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post #10 of 15 (permalink) Old 07-16-2010, 11:30 AM Thread Starter
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Thanks again Dave (or "N" - I rather like that 'cause it sounds like something from James Bond). I appreciate the info and picture. It makes life much easier to have the forum's own Haynes' manuals since the actual Haynes makes a lot of assumptions...like the only time we'll replace this seal is when we take the tranny apart. Dinner is at 6 today, but somehow I don't think you'll make it. Oh well, next time you're up this way, let me know.

If the force is with me, will it be easier to get my bike onto its centrestand?
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