DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 12 (permalink) Old 12-31-2010, 4:02 PM Thread Starter
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DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

I did some searching on here and this seems to be a pretty consitent problems on bikes approaching 15K miles or more. Basically you notice a small amount of oil coming from the weep hole on the right side of the bike. This is caused by the gasket on the balancer shaft going bad. I will show what happens in the pictures. Since there was no DIY for this I thought I would post one as I was doing the project today.

First you need to order the fallowing parts from your local dealer or ronayers.com

658837 49063-1056 SEAL-MECHANICAL 1 $10.16
1087314 92049-1215 SEAL-OIL 1 $6.33
113225 11009-1838 GASKET,PUMP HOUSING 1 $3.85
113226 11009-1839 GASKET,PUMP COVER 1 $5.04



I would also recommend orddering a new oring for the pipe that runs to the engine. I didnt replace it cause I didnt know about it but I would suggest doing it anyway.

here is the microfiche blowup of what we are doing.



So here we go replacing it.

1. Get the bike on the center stand and get the bottom fairing off

- 2 phillips screws up front and 2 x 10mm bolts onteh bottom
-slide it off
2.Here is a picture of what the oil leak should look like



3. Get a pan and drain the coolant from the radiator
- remove the 8mm drain bolt - also loosen the hose hat runs from radiator to pump to relieve vacuum
- should drain about 3/4 gallon or so
-set it aside



4. Remove the 4 x 8mm screws from the waterpump cover
-pay attention to put them back in the same hole as one is different


5. Pull the top cover off
- NOTE there are two layers here so make sure you only try to remove the top cover so not to damage the WP propeller
- the tube comes out of the engine
- replace the gasket and set the cover aside


6. Remove the WP propellor
- IT IS REVERSE THREADED - right to loosen it is 12mm
-just unscrew it and set it aside



7. Remove the inner panel
8.press out old gaskets
- rip off the big gasket
- flip it over and pull out the slotted gasket first using a small screwdriver
-now use a 1 3/4" pvc pipe to knock out the other seal carefully






9. put in new gaskets
- put in the seal first using a rubber hammer and your pvc pipe
-put in the rear seal next
10. Reassemble
-put the cover on
- propeller screw on
-top cover on - BOLTS WHERE THEY SHOULD GO
-screw the bleed screw back in and clamp the hose
-refill the radiator (left side of the bike)
-bleed system to get rid of air bubbles.

and your done. any questions feel free to email me.
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post #2 of 12 (permalink) Old 1-1-2011, 10:58 AM
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Re: DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

can this be wiki-d ?

my (sold) ninja 500r page<br />http://rhoderage.blogspot.com/
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post #3 of 12 (permalink) Old 1-1-2011, 12:56 PM Thread Starter
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Re: DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

sure feel free to add this to the wiki
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post #4 of 12 (permalink) Old 1-6-2011, 1:01 PM
smith.p.sean
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Re: DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

how do you bleed the system?
post #5 of 12 (permalink) Old 1-6-2011, 2:07 PM
fog
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Re: DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

You don't. Just fill it to max at the rad cap run the engine a bit ,top off. Fill the expansion tank and heat cycle the engine. afte it's cool re fill the expansion tank as required. If empty . re fill and re heat cycle.
Do not open the rad cap at anytime in this process. and never when hot otherwise. Doing so will break the vacuum and ruin the thermo cycle of the cooling system.

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post #6 of 12 (permalink) Old 1-9-2011, 2:24 AM Thread Starter
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Re: DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

BTW if someone can please add this to the wiki I would appreciate it. I just cant seem to get the editing right.
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post #7 of 12 (permalink) Old 1-9-2011, 9:19 AM
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Re: DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

add that what you are doing is a a basic water pump reseal....rename?

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post #8 of 12 (permalink) Old 1-16-2012, 7:46 PM
RxZ
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Re: DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

Thanks for the how to! I just found this today, but I had to replace these items near the end of last year. Only difference was on my bike the coolant was leaking, not the oil. Same thing though, once I tore it apart you could tell easily that coolant was coming through the weep hole behind one of the two seals that needed replacing.

Anyway, great write-up! Also, in case anyone is wondering, I used RTV instead of new gaskets. So far I haven't had any problems.


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post #9 of 12 (permalink) Old 6-28-2012, 5:13 PM
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Re: DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

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post #10 of 12 (permalink) Old 10-2-2012, 12:24 PM
RxZ
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Re: DIY: Replacing Balancer Shaft Seal AKA - small oil leak on right side seal

And, I am having to do this again tonight. Did an oil change last week and noticed a very small amount of water in the oil. I looked under the water pump, and sure enough there was a little coolant coming out. Same as before. I am hoping this time it only takes an hour or so to do everything, instead of the several hours it took the first time.


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post #11 of 12 (permalink) Old 7-26-2016, 5:25 PM
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The shaft that turns the water pump is that part of the crankshaft. I definitely have found at least one source where the water was getting in my oil, now then do I take the transmission and the cam chain tensioner out of this and put in my Four Fin 1991? I haven't been able to work on this since March or whenever. I thought I was getting the hang of your website a little bit and now I've got a new curve ball coming at me

And install that engine on my 98 frame with a title
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post #12 of 12 (permalink) Old 8-3-2017, 7:51 PM
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Quote:
Originally Posted by mvrk10256 View Post
I did some searching on here and this seems to be a pretty consitent problems on bikes approaching 15K miles or more. Basically you notice a small amount of oil coming from the weep hole on the right side of the bike. This is caused by the gasket on the balancer shaft going bad. I will show what happens in the pictures. Since there was no DIY for this I thought I would post one as I was doing the project today.

First you need to order the fallowing parts from your local dealer or ronayers.com

658837 49063-1056 SEAL-MECHANICAL 1 $10.16
1087314 92049-1215 SEAL-OIL 1 $6.33
113225 11009-1838 GASKET,PUMP HOUSING 1 $3.85
113226 11009-1839 GASKET,PUMP COVER 1 $5.04



I would also recommend orddering a new oring for the pipe that runs to the engine. I didnt replace it cause I didnt know about it but I would suggest doing it anyway.

here is the microfiche blowup of what we are doing.



So here we go replacing it.

1. Get the bike on the center stand and get the bottom fairing off

- 2 phillips screws up front and 2 x 10mm bolts onteh bottom
-slide it off
2.Here is a picture of what the oil leak should look like



3. Get a pan and drain the coolant from the radiator
- remove the 8mm drain bolt - also loosen the hose hat runs from radiator to pump to relieve vacuum
- should drain about 3/4 gallon or so
-set it aside



4. Remove the 4 x 8mm screws from the waterpump cover
-pay attention to put them back in the same hole as one is different


5. Pull the top cover off
- NOTE there are two layers here so make sure you only try to remove the top cover so not to damage the WP propeller
- the tube comes out of the engine
- replace the gasket and set the cover aside


6. Remove the WP propellor
- IT IS REVERSE THREADED - right to loosen it is 12mm
-just unscrew it and set it aside



7. Remove the inner panel
8.press out old gaskets
- rip off the big gasket
- flip it over and pull out the slotted gasket first using a small screwdriver
-now use a 1 3/4" pvc pipe to knock out the other seal carefully






9. put in new gaskets
- put in the seal first using a rubber hammer and your pvc pipe
-put in the rear seal next
10. Reassemble
-put the cover on
- propeller screw on
-top cover on - BOLTS WHERE THEY SHOULD GO
-screw the bleed screw back in and clamp the hose
-refill the radiator (left side of the bike)
-bleed system to get rid of air bubbles.

and your done. any questions feel free to email me.
I would suggest a tiny amount of lube or oil on the shaft and inner seal. I put mine back together dry and the rubber was sticky and when the shaft spun for the first time it tore the seal. I had to take it all apart again
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