Well pulled the gearbox last night, gotta love working on these bikes it only took me just over on an hour to have the box on the bench.

Pulled it out to do the seals but found that the leak is actually coming from the front cover.....Damn.

Oh well bit of loctite 573 will fix that, while i have it open i will have a quick look at the bearings. Funds and time don't allow me to replace the bearings just at this point(unless they look shagged) in which case no riding over my xmas break. The box seems to operate ok with no noises or anything.

Will do the engine rear main seal and o ring while i am in there though and check and clean the swingarm bearings. I am going to take happy snaps during the job so i can put them up here for anyone that is interested.

UPDATE. I was wondering what to use for sealant for the front cover(manual states loctite 573) its obsolete. Rang Loctites tech department and the product that replaces it is Loctite 518. Comes in 50ml tube costs about $30. Just thought it might be helpful for others who were looking for it.

All this came about when i did the spline lube and found an oil leak, oh well such is the joy of the K.

Here is pics of box. Yellow arrow is seal i thought was leaking and the white arrows are where it is actually leaking where the cover plate mounts to the gearbox.



Some close ups of the leaking area.





Main seal removed.



Inside the cover where it was leaking (arrows)



Swingarm cleaned up and bearings removed. Still toying with painting gearbox,swingarm and f/drive silver.



Another Update.

Got the gearbox back together last night replaced all the seals bar the one on the input shaft where the clutch pushrod goes thru, replaced main seal and o ring on the engine. Put the clutch back on (not fun) and reinstalled the gearbox. Note to anyone doing the clutch, when you match mark all the components don't wash the parts with solvent afterwards!!! OOPS no more marks. The more experienced members on here are now chuckling away to themselves. I'm not used to that many bits in a clutch, only used to clutch & plate pressure thats it. Anyhow i am hoping to get enough time away from my pre xmas list of things to do around the house, to finish putting the bike back together. We weren't supposed to be working today,( i was going to put it back together today) but here i am at work woohoo.

good idea on the pics bert 2.0

All back together now, goes a lot smoother for the lube on the clutch/spline areas. Definitley worth the effort.

Thanks to everyone for the info on the project, made life a lot less stressful.

good one bert 2.0



hope to see you on tuesday ....8.00 - 8.30 ish ish ?

Be there with xmas bells on.

Nice thread bert 2.0 very useful info on the loctite.

BIG D

Good job. Gotta love those centre punches!! (dont wash off!!)

The white paint pens are the best thing and I always write the thickness of the clutch plate and date of the job on the clutch centre. It pays when you pull it down next time.