2004 gearbox removal SOLVED

Discussion in 'Maintenance' started by TonyEmm, Apr 14, 2022.

  1. TonyEmm

    TonyEmm Member

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    Hi guys
    So after doing a ton of work over the winter and getting my bike running so so sweet the shaft seal has developed a leak.
    Basically I now to repeat a fair chunk of the work to access the seal. Please don’t say pull it out from the front because the seal is lipped and retained by the casing.

    Has anyone removed the gearbox without dropping the exhaust and oil pan?
    I can’t get the pump drive chain off without removing the lower drive sprocket and it looks like the only access is from below. That wasn’t a problem last time because I had the bike in a thousand pieces but I want to avoid it this time if possible.

    Any tips?

    Thanks
    Tony
     
  2. TonyEmm

    TonyEmm Member

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    Fresh pair of eyes today. Managed enough wiggle room on the top sprocket to drop off the shaft and allow chain removal. After that gearbox removal is a two minute job, gotta love a cassette box.
    Thanks
     
  3. TonyEmm

    TonyEmm Member

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    Pressing out the countershaft crankcase bearing with the engine still in the bike was not a two minute job. All to change a fricking seal, I dread to think what a dealer would have charged to do the job.
     

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