help!!! clutch cover gasket leaking!

[tconroy]

I need to replace my gasket and never done this before to the bike. Is there any problems Im going to be faced with? Do you also have to replace the clutch shaft seal or will it be ok after I take the cover off. It looks pretty easy and thats what Im worried about!!! Please help!!!!!!!!

[redliner1973]

No big deal at all, except for maybe the pain of taking those cheap phillips-head screws off to get the cover off ( my 'GK has bolts, so never had the chance to experience it). Other than that, it is easy and straightforward. Pull the cover, replace the gasket, reinstall it. just make a note of what position the clutch arm is in, and make sure it splines back in the same way. you should not have to replace the shaft seal unless your leaking there to begin with.

[Anonymous]

replace the shaft seal anyway, its cheap.

[tconroy]

gear casing

my bike also has 8mm bolts not phillips screws.My bike was made in 83 for the kcmo shriners and is all original with windjammer fairing and audiovox stero with jetter speakers and jetter hard case pakage.Everything is in perfect working order still!!! does the case lift straight off the clutch shaft? I ordered a clymer manual but it wont be here for a few days and I want to get this leak fixed asap!!!

[redliner1973]

Than you have it easy since you have the bolts!

1. Put bike on sidestand. This way you wont have to drain oil out.

2. Remove cotter pin from clutch cable pin at the clutch cover

3. Remove pin, set aside.

4. Remove all 8 bolts ( I think 8), and lay them out so you see exactly where they go back in, they are differing sizes.

5. Pull cover straight back.

6. Clean mating surfaces of all old gasket - Be careful not to gouge!!

7. Install new gasket. Sealer is usually not needed, but if you insist, use Permatex H-3 or Indianhead gasket shellac (Autozone usually has either) try and stay away from silicone sealant.

8. Reinstall cover making sure to re-align the splines on the shift lever. It should go right back on without having to re-adjust the cable.

9. Reinstall clutch cable pin.

10. Refill with any amount of oil lost (some may have come out when cover was removed)

11. Run engine, check for leaks.

That should about do it. if you run into any probs, post back.

[Anonymous]

If you can roll the bikes tires up on a 2 X 6, or 2 x 8 board, it will lean the bike over more when on the side stand. You will not lose, or drip, as much oil when the cover comes off.

[tconroy]

thanks tim, but.......

what year is your bike I have an 83 gs 650gl and I have a screw that holds the pin in the clutch lever arm. Couldnt you just take the clutch lever arm off the clutch shaft or would the pin be in the way?I wish I could send a picture to show you.Im sure I will have no problem doing it since you basically walked me thru it. Does the clutch shaft come off with the cover if you pull the cover straight back like you said,or do you have to raise the cover up over the shaft?????????

[redliner1973]

My clutch 'lever' is only held on by a pinch bolt. It is mounted very similar to the shifter lever, I.E. clamped on a splined shaft, with the lever tightened by the pinch bolt. the pin I am referring to is the one that holds the clutch cable end to the clutch lever at the case. You should be able to just pull the cover off, and the shift lever will come with it. you dont have to do anything to it.

[gspaul]

The shaft is set in the cover,just pull the cover straight out.

[gspaul]

OOPS! Yes unbolt the clutch lever and take it off.

[Mr. Jiggles]

BTW, I tried gasket remover for the first time last week and was amazed at ahow well it worked. No more scraping to the point of gouging. Just be careful to not spray into the crankcase or onto the clutch plates.

[tconroy]

clutch lever

thanks for the help. My gasket should be here friday.Good saturday morning project,then I can go ridin!!!!!!!!!!!