I have a '04 650 vtwin the problem I am having is that the right rear axl seal keeps leaking. I have replaced it 2x now (thinking I screwed up the first time). Both times it starts to leak within a few miles. The axle looks great, there are no marks or dings. There is how ever a small mark in the metal shield on the inside of the axl that protects the seal. I cannot keep replacing the seal to ride 2-5 miles. Also is there an easy way to remove the axl? I have been doing it with a large slide hammer connected to the outer joint but to day it came apart to so now I have another thing to fix in order to take the bike on our holidays. Any help would be great.

 

How much fluid are you putting in the rear diff? If your like most people and filling it up to the fill hole, your putting too much oil in it. The proper level should be 1" below the fill hole. Otherwise, I'd check on that burr you mentioned. As for the axle puller, the proper axle puller pulls on the inner CV joint. There's a spot on the inner shaft, between the gear case and the boot, where a "U" shaped sleeve slips over the inner CV, and the slide hammer fastens to that.

 

The front diff. is filled to 1" below the fill hole and the rear is filled to the hole,the front actually has a screw on the side you take out and fill to it.

Are your bearings bad?That will do it.

 

Well I've got about 4 hrs into removing this axl and no luck at all.

Diginit: I have not been overfilling the rear diff, like yo say I have only been filling it to about 1" below fill hole. Also there are no notches on the inner joint for any kind of tool.

heyyou: the bearings should be good as the bike only has 500mi on it. This is something I will check though if I ever get the axl out to check them.

I phoned the local dealer for info and was told to bring it in Friday and "maybe" they would have a chance to look at it. Maybe is not enough we leave on holidays Monday afternoon. I'm realy starting to wish I had never purchased this bike for the wife.

 

Sit on the floor with your feet against the frame of the wheeler,push the axle in and give it a good yank,repeat untill it pops out of the diff.Give 'er heck dude,it will come.

 

The only things that make sense are either the seal is being put in wrong or there is something wrong with the axle or the housing. Not much else it can be.

 

It's finaly fixed!!!! The problem turned out to be two things: 1 the vent hose was plugged causing the diff to pressure up pushing out the oil and 2 I think I may have slightly over filled it. I filled it with the bike still on the jack. [img]i/expressions/face-icon-small-sad.gif[/img]

Thanks every one for all your help and ideas.