Removing Shift Cover Gasket, What's the secret?

[thewright1]

Hi Guys,

I ended up using that 1/4 wood carving knife and some carb cleaner, and that did the trick My first question is, does this look like it's been put back properly (from what I could see in my users manual, it looks correct) but I wanted to ask you guys if it looks right before I put everything back on and fill it with oil.

My second question is in regards to the gasket. It was a pain in the bunz to get that that thing off and almost impossible to get it off without scratching a little bit of the surface. You can kind of see what I mean when you look in the lower left corner. Anyway, how do these look to you all?

[petejw]

with regards to the last pic
the shift drum and lever dnt look aligned.

put it into second gear,
and see if the shift drum aligns with the line
on the shift lever.

if you have a clymers its on pg 126
fig 48.

[bikerphil]

Put it in 2nd gear and make sure that small mark on the shift drum lines up with the mark on the shift pawl. If it does, you should be good. If it's off, correct it by loosening the nut at the lower right side and turning the bolt with a screwdriver, then re tighten.

As for the scratches, shouldn't be a problem. Put a thin layer of RTV on the gasket first.

[trbig]

I think it's all together fine. The lines on the shift drum will line up fine when the bike is in 2nd gear... which it isn't. Looks like it's in neutral.

With regards to the gasket... Yup, in the area that cover is in, it makes it a PITA to clean up old gasket. That's why I don't use one there. I put Tribond/1194 that is used to put the cases back together when splitting the motor. Just about every bike shop will sell it.

Put a bead of it on the cover.. wait a couple minutes until it skins over.. then install the cover. Mine has never leaked there or at the clutch cover that I use it on. If you ever have to remove that cover again, the Tribond stays flexable and you can just peel it up.. no more grinding and scraping.

Just a suggestion.


Tod

[trbig]

This is what I was talking about. All the marks in red will line up when the transmission is in 2nd gear.








Tod

[thewright1]

Cool, thanks for the info guys. Tonight when I get home I'll put it in second and then send a few more pics your way.

[79XS11F]

I have always used slotted blades from carpet installers banana knifes. They are real sharp and do not dull out too quickly. I use that to get the bulk of the gasket off and then soak what's left with the gasket remover. After soaking it down a few times and waiting i then scrape it off with the edge of the blade held at 90 degrees to the gasket surface and always move the blade along the surface as compared to across the surface. That way if I do manage to gouge the surface the damage is not as likely to create a leak.
Rob

[thewright1]

ok guys,

I put the bike in second and took a few more pictures. I took the pictures from my iPhone so they are no where near my first few pictures that I took (in terms of clarity) but hopefully you'll be able to see if everything is lined up correctly.

[DGXSER]

Yep, still all good. More important to see that it shifts through the gears properly. Sometimes (most times really) when shifting the bike with it not running, you have to spin the rear wheel by hand to get it to fully shift. But it should go through all of the gears completely up and back down again.

[fabricgator]

I just love this as a gasket scraper, I originally bought it from the StrapOn truck but find it at the hardware store. It is sharp and will blend scratches as well as it is comfortable and can remove gasket in layers... I also use a angle die grinder with a soft 2" scotchbrite wheel...

Bahco / Sandvik Triangle Scraper 625

http://www.jamestowndistributors.com...le+Scraper+625

About 26.00 plus shipping...

[thewright1]

I just love this as a gasket scraper, I originally bought it from the StrapOn truck but find it at the hardware store. It is sharp and will blend scratches as well as it is comfortable and can remove gasket in layers... I also use a angle die grinder with a soft 2" scotchbrite wheel...

Bahco / Sandvik Triangle Scraper 625

http://www.jamestowndistributors.com...le+Scraper+625

About 26.00 plus shipping...

Now that would have definitely came in handy!