Okay I finally got this job done last weekend at just over 16k miles. I had never done such work myself and thought others might benefit from my novice observations.
First it would really help if you have an extra set of hands -that alone would have helped me quite a bit.
But it helps you if understand and organize this process before you even get started. I printed out gadgets info on rear tire removal and swingarm removal. Then I studied my Kawasaki 05 Nomad service manual to make sure I knew what I was getting myself into. And of course I scanned through this thread a bit. The following is not intended to replace the material mentioned above
-but rather is just a few observations of the work I did and stuff I made some mental notes about.
Make sure you have the right tools:
Metric allen head wrenches, metric socket set
(make sure you have one big enough to fit whatever size bolt your swingarm uses), Torque wrench
(standard bar type from Sears will do), Circlip plyers
(need to be skinny with long reach to get into the slipjoint -I used the screw type criclip plyers), and obviously some type jack/lift
(need to get the bike about 14" in the air -I use the Harbor Frieght jack).
The process is: 1)remove rear wheel, 2) remove final gear case, 3)remove swingarm, 4) remove propeller shaft. With propeller shaft in hand you will remove the slip joint and begin the lube process. Lube slip joint and re-attach to shaft. Lube swingarm bearings. Lube front driven gearing (near transmission) and re-attach shaft. Re-install swingarm and re-install final drive. Lube final drive splines and rear wheel splines. Re-install rear wheel.
I gave myself a whole weekend to do this and it was a bit more work than I had expected, but I think that was mostly due to my cautious nature and the fact that this was my first time. And I was quite sore on Monday from all the getting up and down and hoisting around that rear wheel
The hardest part as others have mentioned is just getting the rear wheel off
. On my Nomad (with V&H Baggers), I totally removed the left pipe as a unit (two nuts at the jug and two bolts at the muffler). Then go ahead and remove the left side bag support along with the rear cross bar (again thats two hex bolts and two allen head bolts). You might consider going all out and removing the right side pipe and support as well -would make the job a bit easier as they can get in the way, but not like the lefties do.
Now cut the looms holding the brake line to the swingarm -on my 05 Nad there are 3 wire looms to cut (hacksaw, but be careful) and 2 more open clamps that you will just need to spread open. Now remove the brake and bungie the whole thing up out of the way (Nomad upper bag support works good for this). Follow instructions to finish getting the rear wheel off -I strongly recommend putting something under the front tire when the bike is off the ground (it can really rock and roll on the jack when the rear weight is removed).
The rest of the job was pretty much as gadget's site mentioned...
The swingarm and slip joint did not IMO need lubing very badly on my 05 Nomad here at 16k. But that front driven gear (front of propeller shaft, the part just inside the rubber boot) was practically dry. I'm very glad I got some fresh lube there.
Also as others have noted, the slip joint seems to have some of the final drive oil in it when removed. As it glopped out on the floor in liquid form. There was no oil in the swingarm tube that surrounds that joint and hopefully I got it back together without harming that O-ring.
Anyway, just thought a few 05+ Nomad owners might enjoy the read