Gearbox Oil

[AgingHippy]

Hello All

The last time the sun shined (I think it was Wednesday) I went for a slow spin around the country lanes south of York after work. Fun was had but the gears were difficult to change up - I often had to give it a second go to get the gears to change. I had no problem, or any extra effort/noise when going into first. I also noticed some oil leaking out of the engine case (gearbox?) where the gear lever enters the engine (gearbox?).

Now my questions.
1) How do I check the level of the gearbox oil.
2) Could this gear change issue be fixed by adjusting the clutch (as I read somewhere)?
3) How do you adjust the clutch cable?

Any assistance would be appreciated since I would like to pop down to London this weekend, but don't want to feck up the bike.

I have a service scheduled on Teusday morning, but the weekend seems like it may be fairly nice... so don't want to miss out on nice riding weather.

Cheers

[Hobbit]

if its leaking from were the gear selector enters the engine case (primary side) you will/may need to replace the seals, one on the primary and one inside the motor between the primary and the engine.
To check the primary/trans oil on a sporty you will need to stand the bike upright and remove the clutch cover be careful as the torx head bolts holding it on have been known to strip very easily.
if it is level with the bottom edge of the clutch cover opening you have enough oil.
Is your sporty mid or forward control model?
if its forwards you may just need to adjust the linkage to give a bit more throw if its mids try adjusting the clutch at the adjustment bolts attached to the left front down tube inside the rubber protector.

[AgingHippy]

Hi Hobbit

The sporty has foreward controls.

I am afraid I have minimal bike maintenance exposure (13 years ago) so am rather rusty. I assume when you say linkage, you are talking about the steel rod running from the gear selector/footpegs to the section that enters the engine box?

Is it OK to remove the clutch cover prior to standing the bike upright, or should it be stood upright first?

Also, how do I identify the clutch cover?

Sorry about the stupid questions, but I am a newbie!!

Cheers

[Hobbit]

Originally Posted by AgingHippy

Hi Hobbit

The sporty has foreward controls.

I am afraid I have minimal bike maintenance exposure (13 years ago) so am rather rusty. I assume when you say linkage, you are talking about the steel rod running from the gear selector/footpegs to the section that enters the engine box?

correct the linkage is the rod from the shifter to the peg

Is it OK to remove the clutch cover prior to standing the bike upright, or should it be stood upright first?

Stand the bike up first unless you want primary fluid all over the floor

Also, how do I identify the clutch cover?

Clutch cover is the large circular one on at the back of the engine same side as the shifter (left as sat on bike)

Sorry about the stupid questions, but I am a newbie!!

Cheers

Do you have a manual? what year is the bike if its 04-06 i can send you a clymer FOC as its good for guidance and thats it, the HD one is the best to buy if you inttend to do work on the bike, the only daft question is the one not asked

[AgingHippy]

Hi Hobbit

It is a 2003 1200 Custom.

I certainly intend to get a manual. I actualy am bidding for one on ebay.

cheers

[Hobbit]

cool sorry cant help with the manual mines for the rubber mounted ones
any other questions free

[Tony Cross]

Just a thought; have you checked the primarychain tension? Details are in the handbook. Tension cold should be 3/8".

[AgingHippy]

Originally Posted by Tony Cross

Just a thought; have you checked the primarychain tension? Details are in the handbook. Tension cold should be 3/8".

!!

Hi Tony

You could just as well have written in Klingon there for all I understand...

I have loads to learn. What is the Primary Chain? where is it? and how would I check its tension? I assume the 3/8" is the amount of movement up/down or sideways (whatever) that the chain moves. - similarly to how one would check a fanbelt tension?

Cheers

[Tony Cross]

Sorry I thought you might have the handbook that would originally have been free with the bike. Perhaps someone with better computer skills than me could put the diagram on here. Primary case is on the left footside of your bike. Inspection cover is about the size of a £2 coin. When opened you can feel a chain. Press with finger (engine cold NOT running) and the movement shoold be 3/8". You really need to buy the MoCo workshop manual or at least a Clymer for simple jobs. MoCo is best.

[Hobbit]

there is a tool available for doing this check but i have yet to find or be able to get hold of one.
i stand a locking tape measure next to the bike and then using a a flat strip of plastic or metal measure the starting distance then press up with the strip and see how far it moves.
I will try and post a pic from the clymer manual for the 04-06 its the same process just looks different