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Removing 650 shifter cover

Discussion in 'XJ Technical Chat' started by baytonemus, Aug 11, 2011.

  1. baytonemus

    baytonemus Member

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    I was going to take the shifter cover off of my 650 Maxim tonight to polish and buff it, but it's stuck on there pretty tight. As I was looking for a spot to pry where I wouldn't do any damage, it occurred to me that perhaps there's going to be oil in there? I've never had one of these off before and this is my first shaft drive bike.

    Thanks.
     
  2. baytonemus

    baytonemus Member

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    OK, I got the cover off and, for the uninitiated like myself, yes, there is oil inside. I now have more specific questions about how to proceed.

    1) Are there any problems that I could potentially create for myself by removing the two "breathers" screwed to the inside of the cover?

    2) Is the function of the "middle gear oil level maintaining plug" simply to provide a way of draining oil behind it? If I pull it will I need to replace it? And, if I replace it does it need to be installed with a sealant? (If so, anything special - RTV?)

    3) Middle gear oil is just engine oil from the main crank that is pumped or thrown up in there, correct? There isn't a separate fill procedure for that, is there?

    4) Anything else I should do or look for while I've got it open?

    Thanks!
     
  3. baytonemus

    baytonemus Member

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    I'll jump in and respond with an update in case anyone is watching this thread.

    1) Removing these doesn't seem to be a problem. They are just empty aluminum housings with gaskets behind them. The gaskets came off pretty much intact so I was able to make new ones using them as patterns. I would say the most important issue with that is making sure that those gaskets aren't going to overlap with the gasket for the main cover such that you get a double layer of gasket in one little spot.

    2) Chacal told me not to remove this plug. Also, I found the middle gear oil drain plug that I was previously unaware of.

    3) I'm assuming that I am correct about this issue of oil distribution but haven't had it confirmed yet.

    4) Along the length of the bottom of the shifter housing along the outside edge some old, very ugly, tar-like oil had collected. My guess is that this is a result of the bike being mostly on the kick stand (and leaning that direction...).

    Lastly. it's a little tough to tell from the picture in the factory manual, but with the shifter shaft and shift lever properly installed, is it correct that they are laterally offset from one another and the sprockets are pretty much lined up tooth on tooth (not like they would interlock if you pushed them together?

    Thanks.
     

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