Another leak??? CRAP!!!!

[nighthawk11]

Cad, can you check on that gear case thing and get back to me. That would help me out a lot.
Thanks...

[nighthawk11]

oh yeah, and what kind of grease for the splines?

30% Moly grease, which is available at any Honda dealer is the best. I didn't find a spec on the specific grease from Kawasaki.

But the seal seems a more complicated matter than I thought. The manual says to remove the assembly of the ring gear, its bearing, and the gear case backing plate from the gear case, using jack screws to seperate the case. Then cook the assembly in hot oil until about 300^oF & remove the seal with a special bent pick, taking care not to damage the seal surface on the ring gear's hub.

Actually, it's a bit more involved than that according to the manual. They say to remove the pinion gear first, and I don't think you'll need to. But I've never done this procedure on the Nomad, so please take heed.

[nighthawk11]

I can see doing all that to change the larger seal, 92055B, but the smaller seal, 92049B, is on the wheel side of the hub, outside of the gear area.

55B is just an o-ring. That falls right off. 49B is the seal, and that's the one they describe in the manual.

I really don't understand heating the assembly to remove the seal. Normally a seal doesn't require that kind of treatment to remove. Now removing the bearing from that aluminum plate, yeah, I could imagine having to expand the aluminum by heating to get it free. I think you should be able to remove that seal without heating anything.

[nighthawk11]

Well, I do know that less gear oil, or rather, the recommended amount amount, is not causing it to leak for now. Don't know if it eventually will. I'm going to remove the wheel today and take a look. I'm sure it'll be messy in there, and I'll have to clean up and re-grease the splines. If the seal is leaking, I'll take the final drive to the shop and have them work on it. I'm not equiped to heat the drive, nor press a new seal in. Either way, it'll be fixed this week.

If it was really overfilled, some oil could certainly have been forced out the vent hole, and would have leaked out right where you've seen it.

[nighthawk11]

I'm going to hope for the best, and of course, keep everyone updated.

[nighthawk11]

...and if the seal does need to be replaced, and I can't do it, I'll take it to the dealer and have them do it. That should be considerably less than just dropping off the bike.

[nighthawk11]

ok, got the wheel off. The only place I saw fresh gear oil coming from is where the axle goes through the pumpkin as I pulled the axle out. I don't know if that's normal or not. Any hints?
Thanks...

That could be the little seal: the one we didn't talk about yet. Look at that parts diagram again & you'll see it. I think it's 92049a but I'm working from memory here.

The good news is, though you have to take the case apart, you don't need to boil anything in oil to remove that one. You do need a slide hammer according to the book.

[nighthawk11]

yeah, I was thinking it was one of the seals behind the plate. I'll take the pumpkin off tomorrow and get it to the Kawi shop for new seals. I hope I've at least saved a few bucks removing all this myself. I've read how to take it off. Is there anything special I need to know about putting the pumpkin back on?
Thanks...

Torque the axle before you fully tighten the 4 chrome acorn nuts.

[nighthawk11]

Awesome!!! Cad, I appreciate all your help with this. Thanks...