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Forum - Legacy Please see the NEW Forum / Concours C10 / ZG1000 General Chat and Tech / Gear Oil Leak at Rubber Boot
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Posted By Discussion Topic: Gear Oil Leak at Rubber Boot

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Marrsman
03/16/2010 @ 8:18 PM                          
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Hey All,

I have a 2000 with 33k on it.  There has always been a slow leak of gear oil at the rubber boot that protects the drive axle pinnion and connects to the rear swing arm.  Correct me if I am wrong, but examining the Clymer manual, it looks like the swing arm is dry (no gear oil).  So the leak should be occuring with one (or both) of the o-rings on then end of the drive shaft.  Am I correct?  Through reading the other forums, over filling is a problem that cases leaks.  Could over filling cause the leak at the boot, not just at the final gearcase?  I filled slightly passed the fill hole (not knowing any better), last time I changed the rear end oil.  I have not had any problems with the large oil seal in the final gearcase, and have never had to take the swing arm apart.  My hypothesis is that is traveling through the swing arm to the boot.  I am pretty sure that the leakage at the boot is gear oil, as it smells like it (rotten meat).  The leak is not a huge deal, but I am taking a 9000 mile trip and want to resolve the issue before leaving.  

Am I on the right path?  Any one else deal with this?  Any ideas an input is always appreciated.  I am trying to do research before I tear into the bike to reduce headaches.  Also, is there a special material that the O-ring has to be, or will any do?  

Thanks All!

http://i950.photobucket.com/albums/ad348/djmarrs_bucket/VisitedProvincesMap2-1.jpg?t=1264819451

davidsturgis
03/16/2010 @ 8:26 PM                          
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Do you think it could be moly grease that has s eeparated? I know that the driveshaft spline area is usually filled with 2 ounces of grease (I think) and maybe it's running down to the junction and weeping out.

Do you notice any oil loss in the rear end? If it's noticeable you may see levels drop over several thousand miles.

David

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Marrsman
03/16/2010 @ 8:52 PM                          
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There hasn't been any noticable loss in rear end fluid.  It stays pretty consistant.  The seepage has covered the oil pressure sending unit, center stand, and side stand with a thin coat of oil that attracks sand/dirt.  Not a bad hypothesis.  I should take it apart and re-grease it.

U.S.

colinp386
03/16/2010 @ 9:06 PM                          
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If you are seeing oil on the boot, its more likely that it is coming from:

A) The breather union from the top of the crankcase to the bottom of airbox

B) The Bevel Drive Gasket (this is hard to diagnose

C) The Gear Shift Seal.

Try removing the lower fairing clean the whole area up with a good degreaser then take it for a short 10 mile or so run.

A leak is then easier to find easpecially if you dust on some talc or foot powder. My guess would be the Bevel Gear Gasket, for a while they made them of paper and the rear edge blows out. The newer gaskets went back to metal and are much better.

CP




Colin Prior
COG IT Officer

Lake Forest Park WA
COG#7767
AMA#1081764
ROK#20000617

Marrsman
03/16/2010 @ 10:35 PM                          
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Thanks for the starting points.  I checked the breather union and it was bone dry.  The bevel gear gasket is a metal one and also looks dry.  I was able to pull the boot forward and the bevel seal looks dry.  The swing arm, however looks like there has been oil traveling up it, though leaks are weird like that.

I will take your advice.

Thanks!

U.S.

Marrsman
03/20/2010 @ 8:11 PM                          
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Hey All,

The final diagnoses is the front seal is leaking.  I brought to Cycle City in Rochester, MN and had a tech look at it.  He quickly pulled the boot and used some mirrors.  The fluid is traveling the length of the swing arm.  DO NOT OVER FILL THE REAR END.  Lesson learned.  I having the shop do the work on this one.  They are also changing all hyrdolic fluids, coolant, and a valve job.  I could it all, but am sick of wrenching on it.  I farkled the hell out of it two weeks ago.

Thanks all for the comments.  I have always been humbled by the knowledge that people in this group have.:)

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Daniel Marrs
Red Wing, MN
COG #9027

colinp386
03/20/2010 @ 10:18 PM                          
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Glad you got it fixed!

Many folks overfill the rear diff, most of the time it tends to splatter over the rear wheel which aint much fun!

Colin

Colin Prior
COG IT Officer

Lake Forest Park WA
COG#7767
AMA#1081764
ROK#20000617



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