87 KXT 250 cases

[JMiller]

i'm getting ready to split the cases on my T3 to replace the right crankshaft seal. I'm just wondering what gaskets i need and what i should seal the cases with. Any advice would be great. :-D

[Jeb]

My advice is get a factory service manual and follow it. or like 200xbasket said, If you cant wait then get a mechanic. Also I advise replacing BOTH seals while your in there. Remember the left seal can suck air in from behind the flywheel and lean out the engine. which is worse than burning a little extra oil from the tranny. If the right-side seal was bad and you replace just it, the left seal is older now and will become the next weak link. You'll replace it sooner or later.

You'll need a complete gasket set. But there is no center case gasket. I'd have to result the manual to tell you what they recommend for a liquid gasket.

Myself, I would replace the main bearings and check that crank/rod assembly really well while I was down that far. Think about it, if you take the time to do that, you'll have practically a brand new lower end. Or if they check good, you have the piece of mind of knowing the lower end will keep you moving. I would also inspect the internal transmission parts for wear.

And please please please do not split the center cases with a screw driver or chisel and ! Use a case splitter.

[JMiller]

Where can a get a case splitter? and how does it work?

[Jeb]

You can get the splitter from Kawasaki. Its a steel bar that spans the flywheel opening. You put screws through it and into the M6 tapped holes for the flywheel cover in the center case. then you line up the center rod onto the crankshaft and turn and it will press the crankshaft out of the case.

I made a good one a long time ago out of a piece of tool steel. I think the bought ones are pretty cheap from Kawasaki.

Also, be careful with the crank when re-installing it so you don't get the crank halves out of parallel with each other or out of concentricity between the two halves.

Oh yeah, use a flywheel puller for the flywheel. and absolutely do not strike they flywheel to help it along. let the puller do its work. If you tap or hit that flywheel you can knock the magnets off the inside or worse loosen them and they come off sometime while your screamin through the desert. If you do knock one off, all is not lost. they can be re-attached.

[MIK6]

Jeb is 100% correct!! It is a waste of time to only do 1 seal, it will cause more trouble further down the road. I would look into bearrings, and a rod kit if I was that far into a teardown. Throw in a piston and you are set for quite a while.
HAGEN is also making case splitters. I have his prototype here.

GOOD LUCK
MIK6 / mike

[JMiller]

Whos Hagen?

[MIK6]

He is a guy in Germany that makes alot of costume T3 parts. I have a +4 swingarm extender he has made and a few other parts from him. He has been on this board for quite some time. he goes by Marco, Hagen, or GREENBOY on the boards. His parts company is "CRAZY-G-RACING". He builds quality stuff for a very fair price.

mik6 / Mike

[200x Basket]

i have split about 5 tecate cases and have never needed a case spliter nor have i used a screw driver. you will need a fly wheel puller ($13) and i would use a gasket set for a 85 kx250. that gasket set has a thinner head gasket for a little extra HP. use kawasaki bearings!!! dont skimp on them. i use moose gasket and seals because kawasaki does offer a "set" of gaskets. as they said, there is no center case gasket but there is a special sealer that kawasaki uses. dont use permatex. if you have the crank rebuilt spend the extra $$$$ and have it balanced. all the kx500 guys do it and they claim that it really reduces the vibrations. a new piston would be a must as well as cleaning the power valves. if you have never split a case before you will be in for a shock. there are alot of parts in there. a manual will be a must.
chris