I finished the spline lube last week following Fergy's walkthrough. Everything went great with that part. The teeth looked pretty good and I put in a new O-ring and lubed it with Honda Moly 60.
The problem I have now is that when I started loosening the four bolts holding the final drive to the drive shaft some oil started dripping out. I didn't think anything of it and put a rag underneath the bike to catch the drips as I continued removing the bolts. With the bolts removed I pulled the FD off and a larger amount of oil spilled on the floor. You can see this in the pics. It's an old bike that has a lot of signs of other "mechanics" poking around and the only thing I could think is that maybe someone oiled
the splines instead of greasing
them? I don't know, seems pretty dumb when I think about it now.
I went ahead and inspected the splines. Everything looked pretty good. I cleaned both ends of the splines and greased em up and put everything back together.
This is the part where I neglect to check the final drive oil, even though it specifically says to in the walkthrough!
I rode the bike to the gas station to air up the rear tire a little and rode back and set it the garage before I went to work. Came home after work, check the FD oil level. Nothin. I could see oil on the parts inside but could stick my finger in and not hit a pool of oil below the hole.
I looked up what info I could find about replacing the final drive seals. I did find people who had done this on the board, but only for the wheel-side seal. I'm thinking that I have a (major) leak in the shaft-side seal. That was allowing the oil into the drive shaft. The only thing Clymers had to say about it was "take the final drive to a Kawasaki dealer to have the seals replaced."
I'm going to be breaking down the rear end again and looking closer at the seal. I didn't really look at it the first time, b/c I was only checking for the splines. In the Clymers and online I did see that there is a seal there and that you can order a new one, but I have no idea how to go about replacing it myself. That's what I need your expertise on! If anyone can point me in the right direction or give some tips that would be awesome.
I'm also wondering if you guys think my little ride to the gas station with no FD oil is gonna spell my doom or not.
Thanks a ton in advance!
BTW, I would have linked to fergy's write up and my intro thread in the newbie section but can't use links until I have 5 posts...