So I have changed the kicker seal twice. Still have a leak. Thought I was doing the right thing by replacing all the external seals. The kicker wasn't leaking with the old seal, but replaced it with a new one. Wondering if any one has ever had the same issue? Is there maybe a triple walled seal out there or something other than Yamaha OEM seals that don't leak?
 

I replaced my kick-start seal recently, and when I first put it on had a little bit of difficulty getting the internal lip side over the shaft. I oiled the inside of it, and sort of rotated as I carefully placed it in. It could be that when you're pushing it in the lip is collapsing, and allowing the spring to release. Just a thought.

I've damaged kick start seals installing them.  Lip tends to catch on sharp edge.  

I've wrapped a sleeve of thin stiff plastic sheet or brass shim stock around the shaft to guide the lip over the step...  then slip out the shim stock.  

Is the case ok for wear. I remember my YZ465 had bulk wear in the case & was never going to seal well. Was a magnesium case by memory so not sure if they wear more easily.