I think that my drive has a substantial leak. Here are the details. My bike is a 95 Connie and it has been running great for the last 8 years, but over the weekend I found a huge leak, well huge to me. This occurred after a weekend in which I had a rider in which I was doing quite a lot of slow riding. While the last part is probably not the cause, I just wanted to show what occurred during the problem. Here are the pictures of the mess. Any and all help is most appreciated. I am probably going to either replace all the o rings that may cause a leak ($56.56) OR just buy a used final drive hub for about $125 total. Not sure of which is the best deal.
I already looked up how to do it, I used the Clymer guide and from looking at various other threads. So at this point, I am actually going to do both things. I am going to purchase a used final drive, and also replace the o-rings on this one. Also, I have NOT removed the outer seal yet. I have only done a tear down up to the outer seal. I have read about the difficulties in taking that one out, so that is why I have NOT removed it. I do appreciate your input.
That big outer seal is piece of cake and pretty inexpensive too. That is probably where your leak is. Drill a small hole (1/8") and pull it out with a sheet metal screw. Only drill thru the seal because it is aluminum below it. Clean it all down and tap a new one in. I used a nice flat smooth piece of 1/2" oak plywood with a hole in it. I brushed some Permatex gasket sealant on the seal edge just before putting it in.
I replaced the big seal, and then put back together. Filled with gear oil up to the cap. Drove for 10 miles and no sign of a leak. I am very happy with the outcome. Thanks.