I've read the posts about this seal and how the crankcase needs to be split to replace it. Is it possible to get the seal out without doing this ? That is, to get brutal and butcher it out. If this is possible why cant a bearing shop supply a correct size seal but without the lip that locates it in the crankcase (i.e. a normal seal) and just press it in normally. Or is this just wishful thinking? One post mentions a mechanic modifying the genuine replacement seal ( by grinding the locating lip off) and using some sealant to keep it in place. Has anyone tried this? Seems a poor design on Honda's part to make such a simple part ( and one likely to fail like most seals at some time) so difficult to replace. Thoughts? Cheers, Greg McDonald Australia.

Yer it is a ballache to change, but i woudn't advise trying to shortcut this by getting rid of the lip on the seal. Mr Honda must have had a very good reason to have it designed this way, so best stick to it If it does leak again, then you have to get the engine out again and strip it. i woudl do it right first time.

No, the method I'm enquiring about above doesnt remove the engine--that's the point. If it does leak I'm no worse off. Anyone done it or know of it being done? Cheers.

I think that you may be able to get the seal out, but you would have to get quite brutul with it and this may damage the casing. The output shaft has the full power of the engine on it, and i am guessing that is why it has a lip to stop any chance of movement and an oil leak.
The pic isn't great but you can just about see the lip on the seal.



If you do manage to get it out without any damage to the cases let us know how long the new one lasts, would be very interesting to know.