CatAttack,

I just want to clarify - do you mean the entire drive shaft, or just the section of the shaft between the yokes (i.e the 4 bolts in the front and the 3 in the rear)?

If you are talking about that section of the shaft between the yokes, it should simply drop down after removing the bolts. Giving the shaft a slight tap might help.

Are you just planning to change the rear shaft seal? If so, here's what I did. After dropping that section of the shaft, you'll need to remove the big nut (I think it was like 15/16 or 22mm). I used a breaker bar while applying the brakes. It was a little difficult to remove but after much coaxing, the nut came off. Once I got that off, I simply slide out the yoke and carefully removed the old seal, put in the new seal (lightly greased). Use a big socket (I used a modified plastic lid for my grease tube) to gently tap the seal in place. Once that's done, installation should be pretty straight forward...

Oh, it's best to access the rear drive shaft from the top. You have to remove your seat and air box.

If you need pictures of my seal replacement, I could send you some pics. This forum does not allow me to upload pics.

 

I was trying to remove the section of shaft between the yokes. It is called the propeller shaft. I removed the 4 bolts at the front and the three at the rear but it will not drop down. It looks like I will have to either remove the rear gear case or unbolt it and try to move it back.

I think I may have damaged this shaft or what the shaft connects to. I am trying to remove it to inspect it.

My bike is a 2004 400 Automatci FIS. You have a 2003 400 FIS. If you go to Brown's Leisure World and look at the diagrams for the rear drive case gear assembly you will notice that the 2003 and 2004 slightly different. http://www.brownsleisureworld.com/


Thanks

Roger

 

Thanks for your help. I was able to remove the shaft today. I removed the bolts on the front and read of the shaft and also the 2 bolts on the rear gear case assembly. I then removed the air filter and air filter box and was then able to pull up on the drive shaft and remove it. The shaft was damaged where it entered the rear drive case assembly. New parts are on order and should be in by Friday.

Thanks

Roger

 

<div class="FTQUOTE"><begin quote>Originally posted by: swampyjunior

You should get a service manual for your machine before doing this job. From what I remember from the last one I did I did not need any special tools. I can't find my service manual right now as my kids helped "clean up" my garage and I haven't found where they placed it yet.



I seem to remember removing the rear tire, unbolting the lower and then the upper A-arms and then giving the axle a couple of hard pulls and it pops out of the rear differential. Then I used a screw driver to pry out the old seal. You must be careful putting the new seal in so you do not bend its edges.



Then reinstall the axle and bolt the A-arms back on and put the tire back on and you are good to go.



SJ</end quote></div>

Go ahead an blame it on the kids swampy - lol....

 

Buckaroo,

you know how it is? You can only blame so much on the government so we get married and then, after a spell you need more than the wife and the government so you have a few kids right?

I will say my garage is the cleanest it has been in quite some time. Plenty of room to work on the machine now. The way my CV boot fiasco is going I need the room. Looks like I am getting the three B's all the way around (boots, brakes, bearings). So I have decided to replace my differentials seals while I am at it. Problem is I need it for this weekend and its all tore apart!

I am still looking for someone to blame it on!.....do you think a mother in law is fair game?

SJ