Hey
I just found out that I have a leak on the rear "differential" on my Z6. Oil drips from the drain plug, but I haven't yet been able to trace the exact origin of this leak. The seals on the drive shafts seems to be dry, and no obvious fluids from the top of the casing so I am guessing right now that it could be the o-ring inside the rear axle casing (on the driver side). I think the drain plug is ok but I will of course make sure of this before I start tearing things apart....

Has anyone been able to extract a rear "diff" from a Z6, without dismantling the entire rear end or removing the engine? Any suggestions would be greatly appreciated.

/Tomas

I couldn't find an easy way to get it out. The rear u joint on mine is sloppy, but I'm not wanting to go through that much work to do it. Mine leaked and found it to be the axle was popping out. I used a Polaris snapring and it worked to keep it in tight. Worth a look to see if it's seated good. The plug seal is just a copper washer. You could try a new one or flatten the old one with some oil and a stone.

[2015 Z Force 800 53/Trail EPS]

There's a couple of reports on other makes of overtightening the drain plug and cracking the case across the threads. None for CFM though. 

Thank you guys. I have replaced the drain plug and copper seal, but haven't been able to verify if that has helped.

Cosmosdan, you mention a "snap ring, what part is that and where is it located? I've tried to make sense of the construction using the service manual, but that is not all that easy for me to understand. The parts catalog at Alpha-sports do provide some clues though.

Removing the rear axles, these are just "pulled put" from the actual gear housing?

/tomas

[2015 Z Force 800 53/Trail EPS]

Cosmosdan, you mention a "snap ring, what part is that and where is it located? I've tried to make sense of the construction using the service manual, but that is not all that easy for me to understand. The parts catalog at Alpha-sports do provide some clues though.

Removing the rear axles, these are just "pulled put" from the actual gear housing?

/tomas

On the inside ends of the axles there is a snap ring that expands back out after it is inserted far enough to pass the carrier housing. This holds the axle in. To remove the axle, you first push in on the axle to gain as much play between the two as possible, then with a quick popping jerk, pull the axle out. This motion re-compresses that snap ring on a slight bevel that's on the inside edge of that carrier. If it does not release, rotate the axle 90 degrees and try again. 


If it continues to leak from the plug area look for a hair-line crack across the thread zone extending out across the seal surface. I've see this on some where a steel plug was over tightened against an aluminum case.

Hey
I just found out that I have a leak on the rear "differential" on my Z6. Oil drips from the drain plug, but I haven't yet been able to trace the exact origin of this leak. The seals on the drive shafts seems to be dry, and no obvious fluids from the top of the casing so I am guessing right now that it could be the o-ring inside the rear axle casing (on the driver side). I think the drain plug is ok but I will of course make sure of this before I start tearing things apart....

Has anyone been able to extract a rear "diff" from a Z6, without dismantling the entire rear end or removing the engine? Any suggestions would be greatly appreciated.

/Tomas

I removed and rebuilt the rear diff in mine. had to remove both A arms and shocks and the exhaust system. I just unbolted the a arms and pulled the axles, shocks and a arms out in one piece.

Hi

This is excellent information, Big Jim and Kawa, thx a bunch!. i am slowly getting to the point of beginning this mission. To much winter still though. Need to get the Z6 into a heated place where I can determine the origin of the leak.

/tomas

Well, finally made it to the garage and could see clearly that the drive shaft (or rather the housing next to the diff) had extensive play so I disassembled the brake, hubs and stuff and pulled the shaft. Too easy. Need to wait until monday to get to the cf moto parts supplier/service dude to check if the snap ring needs to be replaced.

I used a Polaris snapring and it worked to keep it in tight. Worth a look to see if it's seated good.

Cosmos, is there any chance that you remember a Polaris parts number or the model where the Polaris snap ring came from that you used?

The snap ring was off a 02? Sportsman 400 rear CV shaft. The 500 should be the same. You can check.
http://parts.polarisind.com/Browse/Browse.asp
You can use the advanced with a part number to see all models that part was used