Removing Gearbox Outer Cover -Stuck Gasket

If everything else is good, I think you'll be happy with Phil's work. I am still after 3 years.

Dave
69S

Good warning as I've not had razor blades mare the surfaces as they line up perfect with the seam. You can break em in half or less too to fit in around locating dowels like in the engine cases. Very little tapping pressure evenly all around can create great and safe break free separation force.

I've had Fair Spares machine cover for a seal and worked as well as my DIY on another tranny by a layer of cig. pack foil in the groove then slather in groove some RTV and around too then slip the cover on lightly greased shaft and leave alone for a day. There is some misty oil evidence on either but only after long and fairly hard rides but no drips.

I too had a stuck gearbox gasket yesterday, tried razor blades (gingerly), rubber mallet, pulling at the inspection hole, but outer cover stuck fast. Then I used a long piece of hardwood stick (say 1 x 1/2 inch) and placed it underneath against the drain plug head which I had left in. Using a hammr underneath the bike to tap the stick fairly hard, the gearbox slighlty parted at that end. After that it was eased off parallel. Phew ! Plan is to fit a 'x' seal at the kickstart shaft and so stop a pesky dripping leak. The 'x' seal as mentioned in the forum, has two rims. Also I plan to use Hylomar on both gasket sides, as this doesn't set, making casing parting easier next time. Will update on how I get on.

Peter

UK
Commando 750 Roadster 1971

JohnTy said:

Hi
Having double checked you have all the screws out! use a large screw driver or tyre lever through the inspection cover and find a point for the tip/point of the screwdriver, then use the leverage to add some pressure while tapping the case with a hide or plastic mallet.
JohnT

Click to expand...

This method worked best for me. ^^^

bwolfie said:

I have some drop in x-ring seals that work a treat. I've had them in my Combat for over a year and not a drop out of them.

PM if you're interested in a set. I have several sets left. Also clutch and alternator beleville washers and a replacment clutch retaining clip.

Click to expand...

+1
I got a set of these X Rings from bwolfie a few months ago and just got around to putting them in because the trickle from the kickstart shaft was getting worse. I put them in about 3 weeks ago and not a dribble from the Kick or gear lever.

drones76 said:

bwolfie said:

I have some drop in x-ring seals that work a treat. I've had them in my Combat for over a year and not a drop out of them.

PM if you're interested in a set. I have several sets left. Also clutch and alternator beleville washers and a replacment clutch retaining clip.

Click to expand...

+1
I got a set of these X Rings from bwolfie a few months ago and just got around to putting them in because the trickle from the kickstart shaft was getting worse. I put them in about 3 weeks ago and not a dribble from the Kick or gear lever.

Click to expand...

I'll second that....Mine were put in a couple of weeks ago and no drips !!!

Thanks Wolfie