Gearbox is out so a few jobs to be done.
Started by giving the gearbox a decent clean to get rid of a few years of dirt, grease and oil.
Next job was to replace the main drive shaft oil seal (113-311-113/A).
Clutch release bearing guide removed and holes re-tapped/cleaned.
Oil seal removed, clutch housing cleaned with Prepsol.
Main drive shaft and oil seal lips got a light coating of oil, outer surface of oil seal got a light coating of sealant.
Oil seal drifted in and clutch release bearing guide refitted with bolts torqued to 15 Nm.
Clutch operating shaft bushes next on the to-do list using EMPI Clutch Shaft Fitting Kit from Just Kampers (J10350).
Operating shaft and bushes removed, cleaned up and painted.
LHS operating shaft bush lock screw hole re-tapped/cleaned.
All parts lined up in correct order.
Trial fit to make sure operating within specs. Paint removed from clutch lever end of operating shaft.
RHS bush drifted in then inner surface lightly coated with grease.
Inner circlip, washer, inner rubber bush fitted to operating shaft, then shaft refitted.
LHS bush fitted with securing hole lined up.
Outer rubber bush, return spring seat, return spring, clutch operating lever, outer circlip installed with light coating of grease on bushes.
Tested to ensure correct operation.
Spring washer and lock screw fitted and torqued to 15Nm.
PR
Slight leakage from the output flange oil seal.
Oil seals and circlips replaced.
Contemplated replacing o-rings on the bearing ring but no sign of leakage so decided to leave well alone.
Gearshift housing was next.
New front and rear bushings, front oil seal, shift lever inner ball joint and gasket to be replaced.
Retrieved the bushings from the parts box only to find they were 17 mm not 16.6 mm as required.
Note the difference in wall thickness.
Ordered new ones, received 17 mm in error.
Arranged to swap for the correct 16.6 mm bushes and installed OK.
Unable to source a new gasket so out with the 0.15 mm gasket paper and ball pein hammer. Tap, tap, tap and new gasket appeared.
Finally a quick paint with engine enamel and into storage awaiting completion of other tasks.
PR
Started by giving the gearbox a decent clean to get rid of a few years of dirt, grease and oil.
Next job was to replace the main drive shaft oil seal (113-311-113/A).
Clutch release bearing guide removed and holes re-tapped/cleaned.
Oil seal removed, clutch housing cleaned with Prepsol.
Main drive shaft and oil seal lips got a light coating of oil, outer surface of oil seal got a light coating of sealant.
Oil seal drifted in and clutch release bearing guide refitted with bolts torqued to 15 Nm.
Clutch operating shaft bushes next on the to-do list using EMPI Clutch Shaft Fitting Kit from Just Kampers (J10350).
Operating shaft and bushes removed, cleaned up and painted.
LHS operating shaft bush lock screw hole re-tapped/cleaned.
All parts lined up in correct order.
Trial fit to make sure operating within specs. Paint removed from clutch lever end of operating shaft.
RHS bush drifted in then inner surface lightly coated with grease.
Inner circlip, washer, inner rubber bush fitted to operating shaft, then shaft refitted.
LHS bush fitted with securing hole lined up.
Outer rubber bush, return spring seat, return spring, clutch operating lever, outer circlip installed with light coating of grease on bushes.
Tested to ensure correct operation.
Spring washer and lock screw fitted and torqued to 15Nm.
PR
Slight leakage from the output flange oil seal.
Oil seals and circlips replaced.
Contemplated replacing o-rings on the bearing ring but no sign of leakage so decided to leave well alone.
Gearshift housing was next.
New front and rear bushings, front oil seal, shift lever inner ball joint and gasket to be replaced.
Retrieved the bushings from the parts box only to find they were 17 mm not 16.6 mm as required.
Note the difference in wall thickness.
Ordered new ones, received 17 mm in error.
Arranged to swap for the correct 16.6 mm bushes and installed OK.
Unable to source a new gasket so out with the 0.15 mm gasket paper and ball pein hammer. Tap, tap, tap and new gasket appeared.
Finally a quick paint with engine enamel and into storage awaiting completion of other tasks.
PR