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Old February 21st, 2015, 09:18 AM   #1
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Oil filter's small o-ring doesn't fit

I changed my oil recently using a KN-401 filter but had difficulty changing the small o-ring. I swapped out the o-ring but had trouble putting the bolt back into the plate.

I just ended up continuing on and forcing the o-ring to go through by tightening the oil filter onto the bike. That appeared to just strip the outside of the ring though to make it fit.

Is this ever the case for anyone else here?
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Old February 21st, 2015, 09:26 AM   #2
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.........I just ended up continuing on and forcing the o-ring to go through by tightening the oil filter onto the bike. That appeared to just strip the outside of the ring though to make it fit.......
It seems that you are doing something incorrectly:

http://faq.ninja250.org/wiki/Oil_Change_Procedure

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Old February 21st, 2015, 09:32 AM   #3
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Those were the instructions I followed. This is the step that I had trouble with (or rather the step after putting the o-ring on): http://faq.ninja250.org/wiki/File:4Winterize.jpg

I had a hell of a time trying to force it through back through the plate while people on Youtube were able to pop it on with ease. (https://www.youtube.com/watch?v=otJlx493OXE#t=339 - at 5:40)
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Old February 21st, 2015, 09:39 AM   #4
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Originally Posted by asdfman View Post
Those were the instructions I followed. This is the step that I had trouble with (or rather the step after putting the o-ring on): http://faq.ninja250.org/wiki/File:4Winterize.jpg

I had a hell of a time trying to force it through back through the plate while people on Youtube were able to pop it on with ease. (https://www.youtube.com/watch?v=otJlx493OXE#t=339 - at 5:40)
You may want to file the edge of the hole in the plate, making a chamfer or bevel, so a sharp edge does not grab the new O-ring.
Also, use plenty of thin oil or ATF and a gentle rotational movement.
If the new O-ring has been damaged, it is better to re-use the old O-ring.

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Old February 21st, 2015, 09:46 AM   #5
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The original one also seemed to have the same issue with the outer edge shaved off. I haven't had any leaks with either the old or new ring yet so I might just leave it until next year for my next oil change. I'll make note to check out the bevel to see if anything's catching. Thanks for the help.
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Old February 21st, 2015, 10:32 AM   #6
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