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General Category => General Discussion => Topic started by: Mr Revhead on May 08, 2017, 03:04:36 AM
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So, I need to replace the rear tyre on my 2003 Cali EV.
Thought I might as well get into the leaky rear main seal it has as well. I see there's a few articles about and I've been reading but have a couple of questions:
Haven't found much on the actual replacing of the rear main, am I correct in thinking I can just prise the deal out and drive a new one in easily once I have the flywheel out of the way?
How likely is it my 2003 bike has the plastic cage bearings in the gear box?
How hard is it to improvise the special tools with normal workshop tools? I suspect they will be hard to get and a lot of $$ here in NZ. Or, which ones are vital for the gearbox, clutch and flywheel?
What else should I do or inspect whilst that far in?
Who wants to come do it for me for $100? :kiss:
Progress: https://goo.gl/photos/U6bnBZw83bzNS76N8
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are you sure the leak is motor oil and not gear lube?
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Make sure it's not just the breather hose, too.. :smiley:
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Make sure it's not just the breather hose, too.. :smiley:
Also check to make sure your crank case breather valve is working.
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There are a LOT of other leak points. Inspect them all.
It generally can be done with normal tools. If you need to replace the rear cover gasket, it is tricky without special tools.
100% sure you have plastic caged bearings unless they were replaced.
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I don't think my bike has that breather hose. Can't see one..
Definitely not gear oil.
Ok so box apart and bearings as well.
This is going to be a big job!
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I don't think my bike has that breather hose. Can't see one..
it's a large hose (about 1" diameter) from the top rear of the block to the center frame tube under the tank, known to crack w/age. can also leak into the bell housing and look like a main seal leak.
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If I'm not mistaken (and I usually am, ask my wife :laugh:), the '03 has the breather hose coming out of the timing cover.
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If I'm not mistaken (and I usually am, ask my wife :laugh:), the '03 has the breather hose coming out of the timing cover.
Yes, somewhere in 2003 they put the breather in the timing cover.
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Thanks guys.
Pretty sure mine has the breather at the front.
Turns out I can hire the tools from Moto Kiwi here so that's one thing sorted.
Guess I just get stuck in swinging the spanners!
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Good luck :thumb: :smiley:
Let us know how it goes!!
Tom
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Good luck :thumb: :smiley:
Let us know how it goes!!
Tom
ditto :grin:
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I will, but don't hold your breath, seeing as it needs a front tyre as well, and removing the front helps crabbing, I reckon I'll change the fork oil etc at the same time. And while it's all apart I'll give everything a damn good clean and polish. So it'll be in bits for a month or so!
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Sent u a pm
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Well started today...
Worst part so far was getting the bloody air box out.
https://goo.gl/photos/p1DbXbvEncrpVZ6y7
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Aha :grin: We have the same colour bike :thumb: Following your thread with great interest as my RMS should probably be replaced too.
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Well started today...
Worst part so far was getting the bloody air box out.
https://goo.gl/photos/p1DbXbvEncrpVZ6y7
Just wait until you try to get it back in.
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Well started today...
Worst part so far was getting the bloody air box out.
https://goo.gl/photos/p1DbXbvEncrpVZ6y7
Time to throw that airbox out.
This is what I do with my Guzzis.
http://wildguzzi.com/forum/index.php?topic=85626.msg1350535#msg1350535 (http://wildguzzi.com/forum/index.php?topic=85626.msg1350535#msg1350535)
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Righto, been busy and got the gear box out today, all pics so far:
https://goo.gl/photos/U6bnBZw83bzNS76N8
Some are just for my reference so won't show much of interest.
I might have an issue with the drive shaft to bevel drive coupling. It's very dry on the bevel end and the coupling seems to be stuck fast to the shaft :( Not sure how I'm getting that out yet.
I assume a high moly grease is used on those splines? I don't think this was lubed right from factory.
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I assume a high moly grease is used on those splines? I don't think this was lubed right from factory.
The main thing is to *have* grease to stop rust/fretting. Looks like Luigi struck again..
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So it would seem my leak is probably the bearing housing gasket :(
I've checked the bolts are tight. Interestingly the lower 2 bolts are blind and NOT open to the sump as I've read in many places.
Oh well back together it goes. If it still leaks then at least I know what it is and it's not a major problem.
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So you going to open the gearbox?
Personally I wouldn't bother unless you have an issue.
However if you are and you want to replace the input and output bearings Pete might be able to help you.
If going in that far then it's also worth checking the shimming on the selector drum. Improving on standard can sweeten the gear changing of the box.
Standard Phenolic caged bearing on the right replacement on the left
(http://i951.photobucket.com/albums/ad355/Old_Jock/Guzzi/Gbx%20Input%20amp%20Output%20AC3%20amp%20ATN9_zpsp9hfszgg.jpg)
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Oh yeah I did that. Replaced both and shimmed the drum :thumb:
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So it's FINALLY going back together. Resorted to taking a couple days off work to get a chance to work on it uninterrupted.
I have to say trying to get the U/J and bearing back in the swing arm is *@#$ of a job :thewife: Then getting the swing arm in and lining up the splines isn't fun either!
And the air box... This thing is lucky i love it!!
But should have it all back together Monday. If I get things clean, those spoked wheels look nice, but man that are a prick to clean!
Was going to do the fork oil as well, but I don't have anything large enough to undo the caps, so that will be another weekend.
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Mr. Revhead,
Did you end up replacing your rear main seal mate? :smiley:
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I did, but only because I was in there. Turns out the leak was from the rear main bearing carrier gasket. Whole new level of hassle doing that, so I tweaked the bolts up and if that doesn't fix it, tough. Coming from there it was only leaking straight down and not being flung all over the place so it won't bother the clutch.
FYI 2003 Calis, the two lower bolts in there, are NOT all the way through. They are blind holes contrary to a lot of things I read.
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Well started today...
Worst part so far was getting the " bloody" air box out.
How do you know when to use the word "bloody"? When you go in a whorehouse, do you ask for some "bloody" women?
Thanks,
Tex
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I did, but only because I was in there. Turns out the leak was from the rear main bearing carrier gasket. Whole new level of hassle doing that, so I tweaked the bolts up and if that doesn't fix it, tough. Coming from there it was only leaking straight down and not being flung all over the place so it won't bother the clutch.
FYI 2003 Calis, the two lower bolts in there, are NOT all the way through. They are blind holes contrary to a lot of things I read.
:shocked: You were *right there.* It's generally no big deal to pull the bearing carrier.. (?)
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Everything thing I read suggested it was quite the job as it's a very tight fit and is pressed out...
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Well, all back together and so far so good! Only been for about 10kms shakedown run as the weather was about to turn NASTY.
Nothing fell off! No leaks either... Time will tell on that one!
One tip: The spacers for the two bolts that hold the frame together and the exhaust mount/rear foot rest bracket, they go on the OUTSIDE of the frame. Otherwise they space the nuts out and jam your swing arm. lucky I spotted that before riding it!! Just goes to show, no matter how many times you check something when you're working on it. It always pays to check again!
Now, fingers crossed for some sunny weekends so I can get to riding this thing again, I'd forgotten how cool it sounds! :bike-037:
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So, decent test ride today in the sun :thumb: Goes great, shift is MUCH better now. Neutral light is very iffy...
And the leak is still there. Bugger.
First 2 short rides saw it dry as anything. I had the oil half way up the dip stick, topped it up with another 300mls which saw it about 4/5 up the dipstick, and it was leaking after 150kms.
Might try running it around the half way mark and see how it goes. It was always worse straight after an oil change. I always thought the dipstick marks were out, 3 litres was never on the full mark...
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How much oil do you use for a fill? More than 3 liters is going to get pumped out somewhere.
I'd fill with a measured amount, read it on the dipstick and recalibrate the dipstick if necessary.
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You have checked the breather hose for cracks etc. I assume?
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I put about 2.5-2.8l in then another 300mls. plus whatever was left in the filter as I didn't take the sump off. Only 5000ks since last change.
So I think I'll drain it and put 2.5 in and see where that is on the stick
Mine has the breather in the front. The leak was around the rear main carrier gasket.
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Of course, sorry. I should remember that as there's one in the workshop right now. I'm on vacation though. That's my story and I'm sticking to it! :grin:
Pete
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What do you do for holidays over there? Can't go outside, everything tries to kill you! :evil:
While I have your attention, can you confirm for me that taking the rear bearing carrier out and reinstalling it with engine in frame is doable? I was under the impression it's a major job needing a press.
But I've found instances where you describe using teo holes and long bolts to wind it in slowly?
Is that true?
If so I might go back in and do the rear main again and fit a new gasket if lowering the oil level a bit doesn't work.
Not that I want to go in... But it's embarrassing having a leaky bum :(
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Yes you can try it that way but it will damage the tops of the threads in the block and so they'll need re-tapping afterwards. It also takes a great deal of care to raise the flange evenly. Far better to use eithe the factory tool or one you've made to a similar design.
Sometimes the flange will come out very easily. Sometimes it can be a king sized PITA.. Make sure you don't break the flange.
Pete
PS. We've just had a week in Townsville in FNQ so there wasn't much to worry about apart from the Crocs, the Sharks, the blue ringed octopus, the stonefish, the fire coral, the taipans the Portuguese men of war and the cassowaries.....:D
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No bears?
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Cheers Pete, I think I'll leave that for a while. I just wanna put gas in it and ride it!! Fingers crossed rechecking the oil level does it, but if not I can live with the leak
I'm not bothered by creepy crawlies etc, but when I'm oz the smallest bug makes me scream and run....
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I'm not bothered by creepy crawlies etc, but when I'm oz the smallest bug makes me scream and run....
Ha :laugh: Wait 'til you see the humans :grin: :wink: :evil:
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No bears?
Only Koala bears [emoji199]
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Ha :laugh: Wait 'til you see the humans :grin: :wink: :evil:
We have lots of Ozzie tourists coming thru Oklahoma doing the RT 66 thing , I tell folks they are harmless , just hand 'em a beer and remain calm :grin:
Dusty
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If my bike needs work, I'll have to pay someone to do it. Not that I haven't done it before, but now I don't have the space, time or tools.😕
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It's the Drop Bears that are worst....
FYI drained the sump, a flyshit under 2.7 litres in there. So I put it all back in. Brings it up to around 3/4 on a screwed in dipstick.
Lets see how it goes over a few more rides.