DragBikeMike wrote on 09/13/24 at 14:43:40:Hey, throw us a bone will ya. Howzabout lettin a little protective coating of dirt & grime build up before you post pics.
I am surprised that you have a leak at that particular o-ring. It's a static joint and the o-ring fits super-tight.
If that output shaft o-ring was leaking, you should have oil tracking all around the inner face of the pulley. How did that face look? Was the nut good & tight?
Well I should have taken a photo prior to cleaning things up. The area was not saturated with oil and grime - there was a thin coating of crap, and the inside of the pulley had a small amount of oily dirt.
Yes the oil limiter orifice is still in place.
Once it was taken apart there was light coating of oil on the splined pulley shaft and the spacer. There also was a light amount of oil on the pulley where it contacts the spacer. The O-ring was a bit squashed from being in that location for 17 years.....and the shaft had a ring of brown stain/rust where the O-ring was in contact with the shaft.
I put it back together with a new seal and O-ring - and just for giggles I took off the Kawasaki front and rear pulleys and put it back together with the stock front and rear pulleys to see where this bike used to be in gearing.
I went for a 30 mile ride yesterday on my local twisty road - and I could not believe how low the stock gearing is! With my tall gearing I am normally riding 4th gear - on this ride I was always in 5th and looking for another gear to shift into! My Kawasaki gearing provides for 4,000 rpm at 70mph.....with the stock gearing 60mph was turning just a bit under 4,000rpm! I rode the entire route in high gear and it certainly would be proper gearing if I was riding like Ruttly and "Going for the Gusto" at any instant - but it seemed like I was just spinning the engine too fast and it just felt and sounded way too busy than I was used to.
I will change the front sprocket to the Kawasaki and leave the stock rear one on and see if that is acceptable - if not I will then put the rear Kawasaki pulley on again.
And the bad news is I still have an oil leak......more on that below.