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Old 10-11-2014, 10:11 PM   #1
marin ktm OP
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Location: Marin County, CA
Oddometer: 324
Shift shaft seal extraction, 990 Adv

Has anyone done it? Mine is leaking and I got 2 new ones (1 extra just in case). I would like to pull the old one without having to pull the shaft itself. How can I get a firm "grip" on it and pop it out, without scratching the engine case or the shaft?

I cut a little groove into the tip of a steak knife and can insert it into the seal, rotate a quarter turn and pull and get some purchase on it, but it is not budging so far.
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Old 10-11-2014, 10:18 PM   #2
REALGRAVEROBBER
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Or drill the largest hole you can in it. Two different holes 180-degrees away from each other. Either use a punch and hammer to try to coerce it to move, turn and eventually peel out,

OR,

use a Cape Chisel (google images) to collapse the seal and work it out.

Use a the old seal, and a piece of pipe, or deep socket to press in the new one. Lubricate the shaft and new sealing surface.

Being careful, you ought to be able to pull this off. I've only done 1 and it went ok.
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Old 10-12-2014, 02:23 AM   #3
Peanuts
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Here's how I did a quick preventative maintenance waterpump seal change, you could use the same idea for the shift shaft.
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Old 10-12-2014, 03:34 AM   #4
dmn0507
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Shift shaft seal is a bit bitchy to get out.
I had luck with a very pointy chisel, made it to rotate a little by hitting it at an angle. After it breaks free use some leverage to work it out little by little.
Some swearing is probably needed.
You can also google images "seal puller" and make one on the fly.
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Old 10-12-2014, 03:35 PM   #5
marin ktm OP
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Got it

Thanks for the good tips. I ended up drilling 2 holes and threading in 2 small screw eyes. Then I looped a couple feet of wire through them and slipped a hammer handle through the loop, gave it some slack and then one good yank and it popped right out!

I almost failed at getting the new seal in straight, but careful, gentle tapping straightened it out as it went in and all is clean and dry down there after a 30 mile ride.
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