[chief929]

anyone replaced one before?
1976 Honda XL250
Will a screwdriver at the edge tap out the old one without ruining the cases?
Neil 617-512-5654 call ANY time...

[SSearchVT]

I haven't replaced one on an XL250 - but have replaced a lot of seals...

Avoid the screwdriver around the outside - at worst try to sneak the screwdrived in against the countershaft.

A trick I've used a bunch of times - drill some small holes in the meaty part of the seal (through the rubber and metal) - be careful!!! Screw some drywall screws into the holes in the seal and use pliers on them to pull the seal out. Hope this helps.

[chief929]

Sounds like a plan. I don't have a garage with a drill but maybe I can bend a pin, slide it into the middle of the seal, turn it and then pull the seal out...or use my trusty 1922 hand drill that my Dad gave me...or better yet, buy an electric one at Home Depot since this will save mucho dinero anyway! We used to use the verb "benjamin" (Benjamin The Hacker) back in the 70s when we were always Mickey Mousing things, back when there was little that hammer and screwdriver would not accomplish...
Thanks!

[stoinkythepig]

Originally Posted by SSearchVT

A trick I've used a bunch of times - drill some small holes in the meaty part of the seal (through the rubber and metal) - be careful!!! Screw some drywall screws into the holes in the seal and use pliers on them to pull the seal out. Hope this helps.

That's the best way that I know of.

[chief929]

Some people also used a very small hole punch and a small pick but I like the idea of drilling it. The new seal will take a few days to come in so I have plenty of time to get the necessary removal tools. I was going to drain the oil but I am breaking in the new top end so I will just lean the bike against something on the other side with some foam against the tank if need be.

[rmbbikes]

Just did the one on mt KTM dirtbike. I just used a flathead and worked it around the seal and it came right out.

KB