MK 111 kicker seal

Kicker seal leaking , old , needs replacing. Kicker is off. What is the best way to pull it ? Thinking of screwing a small screw into it and pulling it out. New one should just tap in with a little Hylomar on outside. Correct ?

I believe you need to pull the outer cover to get to the seal. I need to do this on the Titanic even though it was just replaced and the engine hasn't been fired yet.

All years appear to use an "X" ring except for Mk III, which uses a regular seal. All are accessed on the inner side of the outer cover, so you can't pull one out from the outside and change it. Once the cover is loose, the kicker shaft and ratchet come with it then that has to be disassembled to get to the seal.

Danno said:

All years appear to use an "X" ring except for Mk III, which uses a regular seal. All are accessed on the inner side of the outer cover, so you can't pull one out from the outside and change it.

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The Mk3 kickstart seal is accessible from the outside so it can possibly be pulled as Torontonian describes (but maybe just as quick to remove the cover?).

Just looking at the parts fiche, it appears to sit in a recess inside the cover, but that could be my misinterpretation of the line drawing. It shows the seal on the inside in the exploded view, but if there's a clear bore with no recess I suppose it could be pulled without removing the cover.

Now I'm wondering if the right-shift covers could be machined to accept the MkIII seal?

Danno said:

Just looking at the parts fiche, it appears to sit in a recess inside the cover, but that could be my misinterpretation of the line drawing. It shows the seal on the inside in the exploded view, but if there's a clear bore with no recess I suppose it could be pulled without removing the cover.

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Yes, whoever revised the outer cover drawing for the Mk3 either wasn't aware of the change or couldn't be bothered to alter the position of the seal.

Danno said:

Now I'm wondering if the right-shift covers could be machined to accept the MkIII seal?

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https://www.rgmnorton.co.uk/buy/kickstart-oil-seal-commando-mk3_755.htm

066145 KICKSTART OIL SEAL CAN BE USED TO CONVERT A MK2 GEAR BOX OUTER COVER
PLEASE NOTE: THE MK2 GEAR BOX COVER WILL REQUIRE MACHINING TO ACCEPT THE SEAL

OUTSIDE DIAMETER: 1.44"

THICKNESS: 0.165

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Gearchange
https://www.rgmnorton.co.uk/buy/gearchange-splined-shaft-conversion-seal_3731.htm

RUBBER COATED GARTER TYPE OIL SEAL USED WHEN CONVERTING ALL RIGHT HAND CHANGE AMC GEARBOXES FROM O RING TO A PROPER OIL SEAL. PLEASE NOTE MACHINING WILL BE REQUIRED.

SEAL MEASURES: 5/8" X 1 1/8

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Here in southern Ontario , Bruce Chessell will take your pre MK 111 cover and machine it and fit a proper seal. It was $65 a while back and leaks at this point were a thing of the past. As for my MK 111 seal , it looks like I can safely destroy it with a screw into it and pull it out without removing the outer cover.

Well I got the seal out with a small screwdriver , after removing the kicker. To install the new one I smeared a little Moto-seal 1 in the cover outer side recess. The seal rubber lip did not want to go easily over the kicker shaft as it is square cut not tapered to accept the rubber seal lip , so I smeared a drop of oil on the lip and used a small screwdriver to persuade the lip to slide over. Pushed the metal surround of seal into place enough to finish with a 1" deep socket and hammer to tap-drive the seal home. It's recessed. Kicker is back on tightly using a power bar. Poured Redline oil back in.