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Old 02-20-2011, 08:19 PM   #1
jay02904   jay02904 is offline
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Rear differential/Gear Oil Leak

Rear diff. is leaking....again this time i have figured out the "inside of the screw hole" (if that makes sense...loss of words...where the inner threading is) are stripped ---- i did not do the last service on the bike the kawi dealer did but has since gone out of business. so i am left with the leak the only thing i can think to do is re tap the rear diff screw drain hole to like size #9. any other ideas?
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Old 02-20-2011, 08:26 PM   #2
ringadingh   ringadingh is offline
 
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Rear differential/Gear Oil Leak

Is it the drain plug hole your talking about? If it is just tap it out to the next larger size and replace the plug. Or you can use a helicoil if you want to use the original plug. Either way its not a big deal to fix.
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Old 02-20-2011, 08:48 PM   #3
jay02904   jay02904 is offline
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Rear differential/Gear Oil Leak

wew...that was a relief to hear! yeah its the drain plug...size 7 or 8 i think. thanks you guys are awesome. and i am gonna go with the dunlop elite 3. i will write it up when i get a feel for em.
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Old 02-20-2011, 08:55 PM   #4
jay02904   jay02904 is offline
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Rear differential/Gear Oil Leak

oh and 1 more thing any suggestions on keeping the filings out when i re-tap it? think they may end up inside?
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Old 02-20-2011, 09:00 PM   #5
jay02904   jay02904 is offline
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Rear differential/Gear Oil Leak

maybe a magnet after the fact will pick up the shavings...
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Old 02-20-2011, 09:34 PM   #6
upside22   upside22 is offline
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Rear differential/Gear Oil Leak

The tap should bring shavings to the top as it turns, except perhaps for the last thread or so. They should be small enough that my guess is that they won't be a problem. You could try and magnetize the tap if you are really worried about it. Maybe by taping a small magnet to the shaft while you are using it? I'd tell you to stuff a rag in there before tapping the hole but man! if you lose it what a pain to dig out!
 
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Old 02-20-2011, 09:36 PM   #7
ndbigfish   ndbigfish is offline
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Rear differential/Gear Oil Leak

The final drive is made out of non-magnetic material; like aluminum I believe. Tap the hole and rinse any thing out with kerosene or diesel fuel. Follow this with 75W-90 gear oil that is allowed to drain prior to re-installation of the drain plug.
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Old 02-20-2011, 09:45 PM   #8
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Rear differential/Gear Oil Leak

try putting some grease on the tap as you work the particles should stick to the grease make sure to go slow and keep cleaning the tap
 
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Old 02-20-2011, 10:14 PM   #9
jay02904   jay02904 is offline
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Rear differential/Gear Oil Leak

ok good to know! one last thing you guys using 75w90 or 80w80 conventional or full syn.? thx!
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Old 02-20-2011, 10:18 PM   #10
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Rear differential/Gear Oil Leak


Quote:
Originally Posted by ndbigfish
The final drive is made out of non-magnetic material; like aluminum I believe. Tap the hole and rinse any thing out with kerosene or diesel fuel. Follow this with 75W-90 gear oil that is allowed to drain prior to re-installation of the drain plug.
It really is not that difficult (if you have a lift) to remove the rear tire, remove the final drive assembly (inspect it too) and take it apart to perform this function. Then when you (if you do) re-tap it you can clean it out from the inside. At the same time replace the o-ring and seal as the other potential leaking points. I know it's a bit involved if you've not done it, but that's the only way I'd TAP it. Even a small amount of shavings in there can do some damage and that final drive unit even used ain't cheap. Just my .02cents as I've taken mine completely apart and cleaned it and re-assembled when I did the swing arm service (something else you can do at the same time).
Again if your not inclined to do these things a garage can do it, but like I said not sure I'd want to trust you got all the shavings.

Oh and not to scare anyone but I did see a final drive like this blow apart on a bike once. Not fun, and glad I wasn't riding beside him (or at a light). He didn't loose the bike, but he filled his draws
I think I'd try some teflon tape (very little) around the threads if it's just seeping first. If that didn't solve it, then tap, IF it's the hole it's leaking from?

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Old 02-20-2011, 10:42 PM   #11
jay02904   jay02904 is offline
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Rear differential/Gear Oil Leak

wow now that i $hit myself...hmmm that's definitely the hole it is leaking from i can run my finger across it after a ride or sitting a while and wala there's oil. the bolt just spins loosely when i try to tighten it up too.
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Old 02-20-2011, 10:49 PM   #12
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Rear differential/Gear Oil Leak

If it were me doing this job, I would take Scott's advice. You don't want to take a chance on the tiniest chip or slug getting meshed into the ring & pinion gears, it will make you have a bad day. The differential parts all come out as components, so you don't have to re-shim or realign anything, just put it back together. And while it's apart, go ahead and replace all the seals too.
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Old 02-21-2011, 12:09 AM   #13
ringadingh   ringadingh is offline
 
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Rear differential/Gear Oil Leak

If you retap the hole, just follow the above advice about keeping the filings from getting inside. Grease on the tap will help, and the filings will fall outside until the very end. try to have a clean tap as you break through and only a speck or two may fall inside. Even if it does go in theres nothing inside that will get hurt by a few flakes of aluminium. It will either fall to the bottom or get mashed so fine youll never know they were there.
Ive had my final drive apart, right to an empty case, and they are rather robust inside.
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Old 02-21-2011, 07:32 AM   #14
jay02904   jay02904 is offline
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Rear differential/Gear Oil Leak

ok i will let you know how it goes today!
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Old 02-21-2011, 03:13 PM   #15
jay02904   jay02904 is offline
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Rear differential/Gear Oil Leak

i posted in a new thread but all seemed to work out using 3/8" tap some grease and flushing it through with new gear oil a couple times and then blowing compressed air into the fill plug out of the drain valve. the only thing is the bolt doesn't feel like it wants to go too tight just snug feels like it wants to keep spinning but i stopped tightening. there is a small metal washer...i think i should leave well enough alone.? thanks for all the help
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