TS185 Clutch pinion seal

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TS185 Clutch pinion seal

New postby DaveyTS185 on Fri Aug 04, 2017 10:00 pm

I need to replace the seal on the clutch pinion (where it goes through the casing) but I can't figure a way to get it out. I can't easily lever it out because the pinion is still in place and can't come out while the seal is in place. Any suggestions?
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Re: TS185 Clutch pinion seal

New postby kbzx6r on Fri Aug 04, 2017 10:27 pm

The pinion shaft does come out. You need to remove the little locating bolt immediately below the pinion shaft. Then the pinion shaft will slide inward and you can remove it and replace the seal. The clutch cover must be off to do this. It might be a good idea a good idea to replace the kickstart seal as well while you have access.
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Re: TS185 Clutch pinion seal

New postby DaveyTS185 on Fri Aug 04, 2017 10:42 pm

Yep, the retaining bolt was removed but the pinion wont come out through the seal. I can see the seal flexing slightly when i pull on the pinion to try to withdraw it and the pinion just wont come out. Its not stuck as such, because it rotates freely but the seal is preventing it coming out and the only solution seems to be to remove the seal with the pinion still in place. Not an easy task.
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Re: TS185 Clutch pinion seal

New postby Butcher on Fri Aug 04, 2017 11:02 pm

I had trouble too ('80 TS125ER). From memory the seal needs to come out first? I did replace one on one of my bikes.
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Re: TS185 Clutch pinion seal

New postby kbzx6r on Fri Aug 04, 2017 11:06 pm

To do it from the outside you could try carefully working a small flat blade screwdriver between the seal and the shaft and using it like a lever to pry the seal out. You are right - it's not an easy task. Be careful and pry from side to side. Might be easier to just pull the clutch cover off.
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Re: TS185 Clutch pinion seal

New postby DaveyTS185 on Fri Aug 04, 2017 11:20 pm

Clutch cover is off already, and I tried a small screwdriver to pry the seal out but the pinion shaft is in the way. I will try the self-tappers into the seal trick, see if that works. I've also tried heating up the casing around the seal but it still didn't want to budge
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Re: TS185 Clutch pinion seal

New postby kbzx6r on Fri Aug 04, 2017 11:43 pm

The OD of the seal is rubber coated and it's find of a force fit in the hole. Unfortunately heat isn't going to help with that. I seemed to recall you had to push the shaft IN to remove it, but that was lots of years ago and lots of different bikes worked on. If you really have to dig the seal out to remove the shaft that's a piss-poor design. I have some emergency universal seal pullers for just such situations....
seal pullers.jpg

...and I took a pic of them for you. The Guinness is of course just for scale.

Can you post a pic of the inside of your clutch cover?
Drive it like ya stole it
Currently - 75 TS250, 02 Kaw ZX-6R
Previously - 70 T350, 71 TS250, 72 GT380, 72 TS125, 72 TS250, 75 Yam YZ360B, 72 GT380 diy cafe racer, 80 GS750, 73 TS185, 82 GS1100
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Re: TS185 Clutch pinion seal

New postby Butcher on Sat Aug 05, 2017 2:46 am

I think I replaced mine with a 2nd hand one. I'd be interested in the seals dimensions to add to the manuals data section.

I had a look at the pinion / seal today out in my shed on a clutch cover I have. I think you need to extract the seal and just leave the pinion in there. do screw and pull technique (sounds bad!) and refit new seal.


Oh and mark on the pinion where the lever goes with a scratch so that you can put lever back on correctly. Damage can occur to the Al cover if lever is misaligned.



"The Guinness is of course just for scale." -BS ! :lol:


I have a cover in the shed that I can photograph if needed.
Last edited by Butcher on Sat Aug 05, 2017 2:46 am, edited 1 time in total.
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Re: TS185 Clutch pinion seal

New postby DaveyTS185 on Sat Aug 05, 2017 11:13 am

Well, here's the outcome.

1. The seal size is 12 X 22 X 9. This is marked on the pack, & it's a genuine part. Looks like this is used in a variety of applications so should be easy to get hold of. I had no problem getting mine

2. The pinion shaft will not come out if the seal is in place. There is a shoulder on the shaft & it will not pass through the seal. Either pull the seal out with the pinion still in place (not easy) or lever the pinion shaft with enough force to bring the seal out with it. This is what I did, I wasn't too happy about it, & it does run the risk of damaging something. I don't know what the "official" procedure is - if there is one.

3. The pinion shaft can't be pushed in, to allow seal extraction. The end of it goes into a blind hole

4. Just a tip. if the clevis pin on the clutch fork arm is damaged or goes missing, it's not worth trying to bodge a new one by filing up an old bolt or similar and its not worth paying high prices for a genuine part. Generic clevis pins are available on ebay for pennies, or a local marine store would more than likely have one in stainless for not much more.
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Re: TS185 Clutch pinion seal

New postby kbzx6r on Sat Aug 05, 2017 12:28 pm

Thanks for taking the time to post the detailed explanation and pics too. I think your procedure is now officially the official one. Well done!
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Previously - 70 T350, 71 TS250, 72 GT380, 72 TS125, 72 TS250, 75 Yam YZ360B, 72 GT380 diy cafe racer, 80 GS750, 73 TS185, 82 GS1100
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Re: TS185 Clutch pinion seal

New postby overrun on Sat Aug 05, 2017 4:51 pm

Clevis "pin?" We are talking about the part that binds the female splines together to hold the gearshift lever on? It's not just a bolt? But it's not like the old "crank pins" you find on old steel-crank bicycles where you pound them in and (if memory serves) add a nut for security, is it?
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Re: TS185 Clutch pinion seal

New postby kbzx6r on Mon Aug 07, 2017 5:32 pm

It's supposed to be a bolt...
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...see item 20
Drive it like ya stole it
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Previously - 70 T350, 71 TS250, 72 GT380, 72 TS125, 72 TS250, 75 Yam YZ360B, 72 GT380 diy cafe racer, 80 GS750, 73 TS185, 82 GS1100
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Re: TS185 Clutch pinion seal

New postby Butcher on Tue Aug 08, 2017 1:17 am

Interesting. But I am wondering why that seal would fail???

"I knew it" (my saying). I suspected that that part (splined rod or whatever) / seal would have to come out as one piece. This is because I pictured it going in (fitted / inserted) as one.

Well done. I will add data to manual section (when I can be blowed) and my personal library :) Don't forget to lube the linkage on the arm that lives under the small inspection cover where the cable unites to it :)


Fitting the RHS cover back on is not too hard. Just twist that splined rod a little and jer, jer jiggle it.

Whole job can be done with bike resting on it's LHS on the floor without draining / loosing much oil!
Last edited by Butcher on Tue Aug 08, 2017 1:17 am, edited 1 time in total.
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Re: TS185 Clutch pinion seal

New postby DaveyTS185 on Tue Aug 08, 2017 8:06 pm

Well, i only changed it because I had ordered an extra seal & had the clutch housing off already, for another job. According to the part numbers, its the same seal as on the gearchange shaft and used in many applications on other suzukis. So, it was part of the restoration really, although It also looked slightly manky anyway.

Next up is to replace the driveshaft seal, no doubt that will also be a challenge...
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Re: TS185 Clutch pinion seal

New postby kbzx6r on Tue Aug 08, 2017 8:29 pm

The driveshaft seal (and 0-ring) are easy. Once you get the front sprocket off, the spacer number 32
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pulls right out easily and then you have a nice little gap to get a hook or seal puller into to lever the seal out. Be sure to replace the o-ring number 35 at the same time. Piece of cake compared to the pinion shaft seal.
Drive it like ya stole it
Currently - 75 TS250, 02 Kaw ZX-6R
Previously - 70 T350, 71 TS250, 72 GT380, 72 TS125, 72 TS250, 75 Yam YZ360B, 72 GT380 diy cafe racer, 80 GS750, 73 TS185, 82 GS1100
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