starter gearcover problem

[timbeck]

No good deed goes unpunished, and so it goes.....Just finished a top end rebuild , installed the engine and discovered an oil leak. Best I could determine it was the starter gear cover. I did not mess with it when doing the top end. I took the cover off and foolishly removed the two syamised gears. After cleaning up the gasket surfaces I can not replace the two gears far enough on the shaft to engage the gear going into the engine. Is there a trick ?? Or am I in big trouble.........

 

[gggGary]

Not much of a trick but you're not in trouble. It's pretty much impossible to have something "get out of place" that can't be put back correctly.

 

[gggGary]

Use caution on the top bolt, that also holds the shift shaft guard. It's a bit short on threads and can strip out of the case. IIRC if needed you can go 5mm longer, run a tap into the case for a bit more thread.

 

[timbeck]

I'm on the case, will report back. Thanks Gary.

 

[timbeck]

Well I got the gear and cover back together with a new gasket and some Hylomar, but still have a drip. As far as I can tell now it is coming from the 1 1/2 inch open slot on the bottom case that the lower engine bolt goes thru. I need to lean the bike over and look further....and so it goes.....

 

[jpdevol]

Hmmm. To find an oil leak, sometimes ya have to clean everything dry and then dust everything with talcum powder. The oil likes to travel and it will leave a trail in the powder film - like a snail on a dry sidewalk.

 

[timbeck]

I guess I will have to dust it up like a babies butt. No history on the engine, 12 years in a garage, anything is possible.....

tim