Leaking Final Drive 2003

[Stargazer]

Hi Voyager Nation. Looks like the National Rally was another great success. I have always wanted to attend one but that time frame in mid July just does not work with my schedule.
A few months ago I had final drive issues and thought I had resolved them. Here is the content of an e mail I sent to Carl Leo for his sage advice on my newest final drive problems:
Evening Carl,
I hope this e mail finds you well. First thank you for all your help to the Voyager world. We would be in a hard place without all of your knowledge and expertise. You may or may not recall that we e mailed and talked via telephone a few months ago about my 2003 voyager and the final drive that was leaking around the hub area that attached to the rear wheel. I was asking for help with how to disassemble it to replace the gaskets and seals. I did finally have success in disassembling it but there were some clips that were destroyed as I simple could not figure out how they came loose and were not shown on the breakaway diagram. As a result of this I was then able to find a final drive from a wrecked '95 Voyager for very little $$ and after cleaning it up and servicing it, installed it on my bike. It has worked fine for the last two thousand miles and 4 months but now it has started leaking around the area where the final drive joins to the drive shaft. I have a small pool of gear lube under that spot after each ride and the area shows obvious signs of leaking there. Where the original final drive was leaking around the rear wheel hub is fine with this '95 final drive assembly, of course.
I have considered just biting the bullet and buying a new final drive from Ron Ayers for $1800 as that is cheaper than a new motorcycle (been looking at Gold Wings, BMW's and the Concourse 14).
Do you have any suggestions or advice? With the continued leaks I have low confidence in the motorcycle for any extended day or long ride. I fear I may lose the final drive or lose traction in the rear tire if too much lube gets on it. I love my Voyager and have it set up just like I want it, but can not continue with the final drive problems.


Phil Ward
Pooler, GA

[voyager 2002]

first do you have a vent hole ???? and how full are you filling it??? 2003s did not have vent holes mine leaked till i drilled the vent hole and keep the rear oil 1/2in below fill plug

[Stargazer]

Yes, both my original final drive and the 95 have vent holes. Did both of them myself exactly as instructed and made sure no filings were in the housing, the '03 a few years back and the '95 when I purchased it. And using Carl's advice used a measuring device to ensure 180cc's exactly of gear lube. No more, no less and used dino, not syn 90w gear lube. Last year about this time my drive shaft failed - the universal joint literally broke in two at the transmission coupling. Then late last winter my engine water jacket exhaust ports manifold began leaking - replaced the O-rings - twice (another long story). Picked up a nail in my just new rear Dunlop Elite 3 - replaced that, had the battery go dead, replaced that, but I still have a love affair with the Voyager. Just need that pesky final drive issue resolved. I have two IBA rides planned in the next three months and want the bike in top form.

[voyager 2002]

what seal is leaking ?the input seal on the drive shaft end or the big seal in the coupling ? that the wheel goes to

[Stargazer]

The input seal based on where the leak is. The 03 drive was leaking at the rear wheel coupling seal.

[tbrooks56]

I have a 03 took a trip to Texas this year on it but before we left serviced it up add oil to the rear axle now it is leaking seem to see drops of oil on the boot of the drive line engine end when we filled the axle up it was just below threads when we got back thought maybe over filled so was going to take some out pulled plug and level was down about 1/4 inch down or more so I was thinking oil was coming from there does not have vent hole. Funny thing is my brother has a 02 filled his the same but no leak. just took a trip to NC still leaking. It is leaking on the leftside of bike on the pipe and it ends up on the left bag . Would really like to fix this problem looking for help. If i need to replace seal which one and what is the number. will say thanks in advance for all your help

[Stargazer]

I feel your pain. After failing to repair the original final drive (2003) and the second hand drive (1995) leaking in a different place I have decided to replace with a new drive. It is either that or a new motorcycle. I have opted for a new, yes new, not used drive, and yep it is big $$. Good luck on getting yours fixed.

[HMB Don]

Your Pinon Seal is bad. Carl or the Dealer will get you one for not much for cost. I had to change mine, didn't have a vent hole but after 100k it started leaking. I talked to Carl he told me where to drill, kept leaking. I then took off the diff and removed and replaced the Pinon Seal.

Note: when replacing the Pinon Seal make sure you have the seal facing the so that it keeps the oil in the Diff. When I dropped my Pinon seal in, onto it's seat it spun around and was facing the wrong way.

Tools: Deep socket for the Pinon Nut, Air Gun to remove the Nut, Torque Wrench for Pinon Nut, a couple of sheet metal screws and two pry bars to remove the Pinon Seal. Installing the seal use a deep socket the same size as the seal, use a 2lb hammer minimum, two solid blows should seat the Seal. To Torque the Pinon Nut I put the diff on rear tire which I had Laying on the floor, with another persons help I was able to torque the nut.

69k since the seal was changed. Only use 180cc or 6oz of Amsoil, no leaks.

Don Medina
President
NorCal Voyagers Club
2002 Voyager
AMA Charter Life Member

[Steve in Sunny Fla]

I have posted this before, but it seems largely ignored - there is an O ring at the rear of the input shaft's splines, just before the actual pinion seal. It's VERY easy to cut this oring when replacing the final drive while doing any rear wheel service. This is quite often where the oil is coming from when leaking from the front of the final drive or the boot at the bevel drive end of the driveshaft.

Here's how it works. If you'll examine the input spline area, you'll see that Kawasaki drilled an oiling hole directly into the final drive. This oil hole is to provide oil to the driveshaft slip joint. There is an o ring in the driveshaft assy just ahead of the slip joint coupler; the oring on the final drive input splines acts to seal the oil into the slip joint. this makes a sealed "cup" for the splines to work back and forth in. Cut the seal, and you'll have an unipeeded leak from the final drive into the swingarm. HTH, Steve

[ekap1200]

I agree with Steve, same thing with mine, after 21k miles. not a drop to be found now. Oil will travel up the drive shaft and drip into the front u-joint boot and down on the frame and header pipe. If the seal is shot , boy you will then see some oil, all the oil will leave the final drive. Gene Kap.

[tbrooks56]

that sounds like the problem i have . you would not know the number to the Oring . like to put this to bed. also when they drill the hole for the vent what size drill bit do i use. what do you use for vent .Thanks again for the help
Terry

[VoyKimmer]

I had the same type leak on my way to Degray Lake. Riding 75-80 mph in 100+ temps for hours. Stopped at a gas station and oil dripping from the front boot and oil all over the left side of bike and left saddle bag. It was serviced with Amsoil extreme gear lube 1/4 inch below threads. Have used this type gear lube for 7 years and never had the problem before. With the advice from Carl I drained out the Amsoil and put in 180cc of Bel Ray Hypoid 80/90. It continued to leak until the swingarm tube was emptied and has not leaked since. 800+miles home from Degray Lake in same hot temperatures and another 1000+ miles since I have been back home. I did not take anything apart and did nothing with the seals. Carls advice use Hypoid gear lube only and 180cc's only no more.

[tbrooks56]

went to the dealer today got the seals i need just in case but will try the other solution first and drain and replace the oil and put in the 180cc will keep you posted . Do hope it works .Thanks again for all the good advice

[Stargazer]

Update on my Final Drive:
Thanks to all for the information. Once I pulled the drive off and cleaned/examined it...yes sir the O-Ring on the input shaft on the connecting spline was split in two. I just so happened to have a spare to replace with it. Also when I drained the drive I got back 170 cc of the 180cc I had put in so I had only loss a small loss amount, less than 10%, still the leak was aggravating. I feel confident once I put on the O ring and reassemble it, the leak will be gone, as long as I don't dork up this one. I believe part of the cause may be that I over lubed the spline. There was too much grease in there.