Changing gearbox outer cover gasket

peculierboy

peculierboy

Joined
Jun 22, 2014
Messages
39
Country flag
My gearbox has suddenly developed a leak. I reviewed the process in the manual, but thought I'd ask here first if it comes off without a bunch of springs or things that need to be lined up to put it back together.

I know, probably a stupid question, but I want to be prepared if there are things that need to be lined up when re-assembled. If it's just as easy as removing the primary cover, awesome.
 
Kick start seals are prone to leaking. Runs down and drips off the bottom of the gear box. If you have the cover off be sure and replace both the kick start and shifter seals with the new x-ring or quad type avaiblable from Andover Norton along with a new cover gasket.
 
Last edited:
Ordered a seal, made by AN, and gasket last week from Classic British Spares and it got here in three days, Ca. to Ga.
 
If the cover is hard to come off, refit the gear lever but pointing backwards. It makes a good pulling handle and you can apply some leverage without resorting to slim blades between the covers.
 
I find using WD40 along the sealing surfaces followed by light tapping with rubber mallet/deadblow around the cover, helps release from gasket. The WD gets in between and wallops provide vibration that helps break the atmospheric pressure/suction effect.
PS:
As per Mick Hemmings gearbox rebuild video, I fit the gaskets dry and have zero leaks after three seasons, 8k miles.
 
I usually take an exact knife and bevel the edges of the screw holes, ESPECIALLY the dowel holes, so the cover slides on easier. It also helps to bevel the edge of the dowels with a file. This same trick makes the valve covers go on and off easily.
 
Tornado said:
I find using WD40 along the sealing surfaces followed by light tapping with rubber mallet/deadblow around the cover, helps release from gasket. The WD gets in between and wallops provide vibration that helps break the atmospheric pressure/suction effect.
PS:
As per Mick Hemmings gearbox rebuild video, I fit the gaskets dry and have zero leaks after three seasons, 8k miles.
Click to expand...
I just grease the gaskets
Unfortunately you still get gorillas using all sorts of sealants
 
Hi Peculierboy, I had always some leaking problems with the o-rings from the shafts. of course had x-rings for the shafts. Still was leaking....its annoying!
when you got a older cover with o-rings then I highly recommend to buy a new outer cover (#06.0740) that has oil seals (#06.6145 & #06.3609)
or you got a good machine shop at hand that can modify your cover that the oils seals go in.
Using some Redline heavy shockproof gear-oil is another topic :)
 
baz said:
I just grease the gaskets
Unfortunately you still get gorillas using all sorts of sealants
Click to expand...
Changing gearbox outer cover gasket

Changing gearbox outer cover gasket
Changing gearbox outer cover gasket

Peels off like a sticky note. Now where's my silverback gorilla emogee
:p
 
  • Haha
Reactions: baz
concours said:
View attachment 98907
View attachment 98908View attachment 98909
Peels off like a sticky note. Now where's my silverback gorilla emogee
:p
Click to expand...
Having blown up an xs1100 so badly the rod came out and cut my shin I'm wary of sealants
As the cause turned out to be the sump strainer full of shards of orange instant gasket
And blue hylomar
The bike had had about 8 previous owners
I guess every one of them had added a bit!!!
I really wish I'd dropped the sump and checked it
 
baz said:
Having blown up an xs1100 so badly the rod came out and cut my shin I'm wary of sealants
As the cause turned out to be the sump strainer full of shards of orange instant gasket
And blue hylomar
The bike had had about 8 previous owners
I guess every one of them had added a bit!!!
I really wish I'd dropped the sump and checked it
Click to expand...
"AHTEEVEE" as we say in New England. Whole different animal than anaerobics.
 
concours said:
"AHTEEVEE" as we say in New England. Whole different animal than anaerobics.
Click to expand...
I had some 518 on one troublesome rocker cover. Certainly cured the oil weep. Just had it off to check valve clearance. Noted the 518 did form a pliable solid along the edges and around the studs where it must have pooled a little. A bit concerning b/c it could be scraped off and loose bits were produced.
 
If you are continually getting oil leaks on the ks shaft after installing xrings you may have a burr on shaft. Be sure and polish the shaft with some fine wet and dry before reassembling.
 
baz said:
Having blown up an xs1100 so badly the rod came out and cut my shin I'm wary of sealants
As the cause turned out to be the sump strainer full of shards of orange instant gasket
And blue hylomar
The bike had had about 8 previous owners
I guess every one of them had added a bit!!!
I really wish I'd dropped the sump and checked it
Click to expand...
Loved my xs 1100.
 
baz said:
I definitely would not use sealents on rocker inspection covers
Click to expand...
When I first got my bike, it was burning oil on the left side, starting from cold. The rocker cover gaskets had tons of Wellseal, which was a bas$#@&d to get off the head without falling in. There was a pool of oil in there which looked suspicious. I cleared the head's drain with a bottom E guitar string and it hasn't smoked since.

I guess the restriction in the drain was slowing down the oil return and, on the sidestand, it would dribble down the left side valve guide, into the cylinder? Later, I removed what looked like Wellseal from the sump strainer, either from when it was first applied, or from me cleaning it up. I now use those neoprene gaskets, which have been oil tight and reusable so far.
 
You must log in or register to reply here.
Back
Top