New clutch plates for a Mk3

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I'd try to make it flat again. Milling machine? A different washer just leaves the problem for the next guy.
 

gortnipper

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In checking the outer primary Mk3 cover, I found the area around the drain plug has been polished to a rounded surface.
Not allowing a good seal surface for the OEM Andover red fiber washer.
is there a better Mk3 primary drain bolt seal to install?


View attachment 18139
A smear of RTV on the cover side of the gasket if you want a quick n dirty...
 

Deets55

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Permatex thread sealer on the drain bolt. I never use the drain plug anyway. I have a Cometic gasket that is still leak proof after 4 uses. Once a year I pop the cover to change the oil and look things over. I use ratchet straps to tip the bike to the left to get all the oil out then pull it slightly to the right to stop any dribble when assembling.
 

texasSlick

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In checking the outer primary Mk3 cover, I found the area around the drain plug has been polished to a rounded surface.
Not allowing a good seal surface for the OEM Andover red fiber washer.
is there a better Mk3 primary drain bolt seal to use?
Dowty seals, also called bonded seals, work better than crush washers. I use them wherever I can.

Slick
 

cliffa

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In checking the outer primary Mk3 cover, I found the area around the drain plug has been polished to a rounded surface.
Not allowing a good seal surface for the OEM Andover red fiber washer.
is there a better Mk3 primary drain bolt seal to install?


View attachment 18139
Find a fattish "O" ring that fits the plug, countersink the hole to a depth of half the thickness of the "O' ring, add a greased washer under the head then the "O"ring and tighten.
 

cliffa

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LAB, I ckd thickness of old washer = 0.071"
thickness of new Andover washer= 0.072"

Old shift shaft outer washer was quite marred up from something and this something was the ears of the circlip digging into the washer surface at every install.
And now my new washer is quite marred up from several installs, not complaining simply info about this "curved" circlip.

The question i now have is why had the previous washer been on/off several times?
Is this shift shaft seal leak a continuous issue with a Mk3?

View attachment 18075
Similar to the Thackeray washers on the rocker spindles this sprung clip was probably used to simplify & speed up production. I would be inclined to shim it and use a flat circlip instead.
 

p400

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Drain plug issue, primary cover, i went with a smear of Hylomar.
Reassembled, working , no road test, but have to hold gear lever up with toe to get green dash light to come on.

20200813_PrimaryAssembledNoNeutralLight.jpg
 
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