EV Rear main seal: Frame crabbbing etc

[Mr Revhead]

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? 


Progress: https://goo.gl/photos/U6bnBZw83bzNS76N8

[fotoguzzi]

are you sure the leak is motor oil and not gear lube?

[Chuck in Indiana]

Make sure it's not just the breather hose, too.. 

[Madtownguzzi]

Make sure it's not just the breather hose, too.. 

Also check to make sure your crank case breather valve is working.

[Wayne Orwig]

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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[Mr Revhead]

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!

[fotoguzzi]

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.

[twhitaker]

If I'm not mistaken (and I usually am, ask my wife ), the '03 has the breather hose coming out of the timing cover.

[Wayne Orwig]

If I'm not mistaken (and I usually am, ask my wife ), the '03 has the breather hose coming out of the timing cover.

Yes, somewhere in 2003 they put the breather in the timing cover.

[Mr Revhead]

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!

[Tom H]

Good luck

Let us know how it goes!!
Tom

[balvenie]

Good luck

Let us know how it goes!!
Tom

ditto

[Mr Revhead]

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!

[KiwiKev]

Sent u a pm


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[Mr Revhead]

Well started today...
Worst part so far was getting the bloody air box out.
https://goo.gl/photos/p1DbXbvEncrpVZ6y7

[balvenie]

Aha We have the same colour bike Following your thread with great interest as my RMS should probably be replaced too.

[Wayne Orwig]

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.

[antmanbee]

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

[Mr Revhead]

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.

[Chuck in Indiana]

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..

[Mr Revhead]

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.

[Old Jock]

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

[Mr Revhead]

Oh yeah I did that. Replaced both and shimmed the drum 

[Mr Revhead]

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  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.

[balvenie]

Mr. Revhead,
Did you end up replacing your rear main seal mate?

[Mr Revhead]

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.

[Texas Turnip]

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

[Chuck in Indiana]

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.

  You were *right there.* It's generally no big deal to pull the bearing carrier.. (?)

[Mr Revhead]

Everything thing I read suggested it was quite the job as it's a very tight fit and is pressed out...

[Mr Revhead]

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!