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Greetings to all.. I’m new to this forum so I would like to apologize in advance for any lack of decorum I may display.
I bought my 04 RC51 used. The bike was in decent shape and for the amount I purchased it for, I couldn’t complain too much. But....it did need some TLC. Oil was leaking everywhere. Most were superficial issues, (missing oil pan bolts, shifter and shifter rod seals, oil drain plug gasket etc..) The biggest issue was the counter shaft seal. As most of you who have looked into the issue know, it requires cracking the case in order to change the seal. I decided to “pull” the old one out, shave the lip of the new one, and with the aid of some RTV Silicone “tap” the new one in. I have put 280 miles on the bike since the change, one was 112 miles and not a drop of oil is leaking. After closely examining the old seal, I realized, the point of failure on these seals is at the inner circle, where the seal wrap around the shaft with the aid of a spring band. I’ll try to post some pictures and if anyone needs clarification, I’ll gladly delve into the step-by-step details of the project.
A83BDE33-FB82-492B-A499-51E5EF8F7E43.jpeg Leaking seal. Right below the shaft

5679D47C-7DC3-47E1-9E23-98EF2A2406CA.jpeg This what it looks like once the shaft seal is removed
99E685AD-2065-4286-BB51-0A73AB6DF5CA.jpeg
4D3F84FB-B6DA-4A21-9E14-EBDC6F2CE350.jpeg
B7F60542-E7B5-4C51-9993-0791DDF9DBA9.jpeg The shiny spring bad was the point of failure on the old seal.
57C9141A-1C22-4F02-BC41-49AF7B014A8B.jpeg I shaved the lip down with a slight angle to the interior of the seal to aid with insertion and pin the silicone in the groove (next picture)
8DAB83F0-9D07-45E2-9D03-E62416831A33.jpeg
3DDB4D4B-0082-4124-86A9-A5C2D2981BB1.jpeg I placed the silicone inside the grove using a syringe..oh and I also placed a very thin layer of silicone around the outer side of the seal to serve as lub and subsequently serve as a sealer for any imperfections I created when I filled the lip off.

14744046-4FE3-45ED-851C-1994CC57AA9F.jpeg The new seal
A1A1A461-FD15-4A56-BE67-E0D900E4418C.jpeg The silicone I used

I hope this helps.
 

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2004 Honda RC-51 Nicky Haden Edition.
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Very nice. I love outside the box thinking on approaching a problem. Crazy you would have to crack the case to change out any exterior seal.
 

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This is how everyone does it anyway , except for the filing and silicone , you would NOT normally split the cases to do this.
 
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