drydenad

Can any give me some insight as to what I'm going to encounter when I remove the transmission cover to install a new gasket. Do I need to drain the radiator or do anything else before I remove this cover. Also while I have the cover off, what types of things should I inspect while I'm in there??

kez

Yes You'll Have To Drain Coolant As The Water Pump Bolts To The Case,Watch The Impellor And Seal Behind It.
You'll Also Have To Change The Oil Unless Your Laying The Bike On Its Side.
Also Pay Attention To The Kick Start As It Came Loose When Doing Dads 400 And Gave Me A Head Ache Working Out How
To Fit It Right With Correct Tention Etc.
Might Be Worth Changing The WP Seal,Just Watch Out For Leaks,Some Leak When They Get Old While Some Leak When They're New.

husabutt

I would replace the water pump bearing/seal and the two o-rings on the impellar shaft.




Water pump bearing/ seal contracption.




Water pump impeller shaft seal protector tool to be used when refitting the side cover back on.

Johnf3

Like Kez said, watch the kickstart mechanism. The shaft pulls out ever so slightly when the cover comes off, then when you put it together, the kickstart is locked up, because it hits the inside of the case.

You have to pull the clutch basket and put the kickstart mechanism all back correctly. Don't ask me how I know.

The seal protector tool is cool to have, but not necessary if you wrap the WP shaft with some teflon tape (where the sharp edge is) first.

kez

I Found If You Tap The Kick Start Shaft With A Rubber Mallet While Taking Off The Cover It Tends To Stay Put....Usually