Forum

[Morley]

Hello to all
I am new to the world of RE's having just picked up a 94 Bullet 500 with only 6000k's on the clock (west coast of Canada)
learning lots and enjoying the process and ride. I have a leaky Transmission as the gasket nearest to the kick start side was never put on correctly and is hanging out. it is leaking and my question is can it be changed by simply taking off the cover with the bike in the upright position? If so what are the things to look out for as I do this?

[Leon Novello]

Hi Morley: I don`t know about yours, but my 2000 Bullet doesn`t have a gasket there. There is usually no grease/oil in that section. Any that is there is leaking from the main section behind it. This is not a serious problem as long as you check the level in the gearbox itself is not getting too low.

[Tim NZ]

I presume that Leon is referring to the outer-cover when he says no gasket?


To replace the gasket, first drain the gearbox, if it is still full of grease, then add some light oil (100cc) go for a ride, than drain, and repeat the process several times. The grease is a bugger to get out.


Then remove the outer cover, the Kstart return spring, the mainshaft cover cap, and the mainshaft nut: Left hand thread.


DO NOT disturb any of the gear-change mechanism, no need too.


Remove the five screws that hold the inner cover to the gear box shell, remove inner cover, clean every thing, fit new gasket, reassemble, noting which oil slinger washer on the mainshaft goes where...

[Morley]

Thank you both for the replies.
Funny enough after reading your posts I had a closer look at the exploded view on this site and there doesn't appear to be a gasket on the front cover while mine has one hanging out there. the leak is very small and I suppose for some this would not be a leak rather a weep and don't worry.. thanks again

[PeteF]

Its possible that someone has replaced the grease with oil. This works if the beatings have been replaced with sealed ones. Otherwise it will tend to leak.

[Gwilly]

Sounds like a leaky o ring on the kick start shaft.

Any job that requires removal of the inner cover needs to be planned i.e. you only want to do it once..

So think about sealed bearings, kickstart pawl kit and inner gasket, also good time to change gear box sprocket as clutch and primary case needs to come off for access to the bearing.

All jobs are done with the box still in the bike.. Winter job i guess when the bike can be laid up for week or so..