Another oil leak! Got questions...

[Fixxxer]

OK, guys. I've got another leak that I want to try and tackle this winter... I just replaced my final drive seal and o-ring about a month ago (see this thread), and that problem seems to be fixed. Yay!

Now, unfortunately, I've started to notice a decent amount of road grime and oil collecting on the bottom of the paralever, at the back of the big rubber boot (the one closest to the final drive). I noticed it before I replaced the FD seal, but I just wiped it clean and forgot about it. I haven't pulled the boot back yet to see if there's any oil in there (I need to go get some new zip-ties first), but I'm fairly sure that I'll find some, given where I'm seeing the oil & dirt buildup behind the boot.

I've been doing some searching on the forums and in the repair manual, and based on what others have been saying, I think that it's a bad rear pinion seal (Is that the same as the "output shaft sealing ring" mentioned in the repair manual?). Unfortunately, I couldn't find anyone who had done the repair themselves and documented the process. Most people ended up having it fixed by their dealer. Maybe I wasn't searching for the right things though...

My bike is out of warranty, and I really don't want to pay the dealer to fix it if I don't have to. So, can anyone give me some tips on what needs to be done? I've always liked to do my own work on my cars (and this bike), so I know my way around a toolbox... I've just never gotten into this area of the bike before, so I'm not really sure what's going to be involved.

First off, let me ask: is the rear pinion seal at the back of the transmission where the drive shaft is connected? If so, what needs to be removed in order to get to it, other than the FD and drive shaft? Are there any special tools required (I've got a heat gun and all of the allen-head sockets that should be needed)? If you don't think it's the rear pinion seal, what else could it be? Like I said, I'm sure it's not the FD seal or the o-ring, since they have been looking clean & dry since I replaced them...

Does anyone have a link to a tutorial on how to fix this problem? As I mentioned, I couldn't find one on the forum, and the repair manual didn't seem to address it either.

Any other suggestions and tips/tricks are welcome!

Thanks!

[AntonLargiader]

Pinion seal leaks (what you describe is usually that) are a bit of a pain. If you have the repair manual (it seems like you do) just look in section 33. That very first exploded diagram shows the seal and what is necessary to get to it.

You need to immobilize the output (the wheel flange) so you can loosen the pinion nut, and you need to remove the pinion retaining ring with a special tool. If you want to do the job right, you pull out the whole pinion shaft so you can smooth or replace the sealing ring that the seal rides against. If the pinion is loose, you need to replace bearings.

I haven't ever seen an online tutorial for it; too much specialized equipment for most people.

[roger albert]

Yes, what Anton said. I think you're confusing, at least partially, the two seals it could be.
It can be the seal at the rear of the transmission. That's not that common on these.
It is normally the pinion seal (input/front of the rear drive housing), which is indeed very tough for even a well equipped shadetree jobber. Keeping things immobilized without screwing up splines or housings hand installing the seal is non trivial. My guess, respectfully, is that if you're not even clear where the parts are, or what they're called, that you're better off leaving this one to the dealer. Part of good mechanic practice is to know when to call in help. You have to get the right depth at the end too. Look over that part of the manual (and then take it to the dealer - you'll at least have a better idea why it's best to pay your dealer and feel better about it)

Sorry, don't mean to be negative, and not saying you couldn't do it. Just not recommending it.

[Fixxxer]

No offense taken, Roger! That's why I asked! Thanks for the honest opinion!

I'll give that section of the manual a good look-over, per both of your suggestions, to get a better idea of what's going on in there. But, I think I'll heed your advice and leave this one to the people with the right tools.

Maybe I'll ask for cash for Christmas this year...

[ExarKunONe]

Can you post a pic?

[jduke]

Fixxxer - exact same problem I have. I think I'm going to send mine to Anton and let him use his knowledge and his tools....

[throttlemeister]

Are you sure it is actually oil? I had something there that looked like oil, but upon further investigation it turned out to be gasoline coming from the overflow tube, which after refilling being splattered over the FD while riding and collecting dirt after that.