Replacing a Gasket - Horizons Unlimited

**OXXT** · #1 17 Jan 2003

I own a 95 Xt600. It looks as though the gasket between the right hand side cover and engine has developed a leak just under the oil line. I am just wondering whther anyone has had to replace this gasket before and if so how difficult is the job. It looks as though I would have to disconnect the oil line and then unscrew the keyed bolts. But I'm not sure what I'll find behind this cover. Just wondering if anyone can help??

Thanx

**GeoffE** · #2 17 Jan 2003

Recommend you get a Haynes manual.
I think this is the cover I have just taken off my bike (3AJ) to fit a kickstart and the mechanisms - the Clutch cover?
First I drained the oil, remember this is a dry sump engine and use the recommended and long-winded procedure. Remove the footpeg/brake pedal after disconnecting the linkage to the rear master cyclinder (so as to get at all the cover bolts). Then undid the oil-line bolt on top as you mentioned, taking care of the copper washer.
Then you can undo all the cover bolts (they are different lengths, so save them in order) and then take the cover away from the gasket - it needs a bit of help if gasket gue has been used as well). Nothing falls out, and you are just looking at the Clutch and other cogs. As well as the Clutch Cover gasket, I think there are a couple of small rubber ring gaskets that should be replaced as well, perhaps the copper washer for the oil-line too?
Apologies if this is too much info.
Geoff

**itchywheels** · #3 18 Jan 2003

Geoffe
Have you got you pin that sits in the crank case, that the kick start spring fits onto ?[easy to over look ]
If not I have a brand new one I can post to you [FREE].I ended up with 2 when i did mine.
you can e-mail me direct on tenere@ntlworld.com

**GeoffE** · #4 18 Jan 2003

Hi Gary,
I have a new one fresh from Yamaha, thanks for the offer though.
I believe "Geoff van de Merwe" on this forum would be interested though, as he is looking to do this upgrade also?
This part appears to be impossible to extract from the engine on a doner vehicle.
Thanks again (I have emailed you also).
Geoff

**Grant Johnson** · #5 18 Jan 2003

OXXT,

Your email address in your profile is bad and I keep getting bounces when people generously try to help. Please correct it by clicking on "Profile" near the top of every HUBB page.

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Grant Johnson

Seek, and ye shall find.
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One world, Two wheels.
www.HorizonsUnlimited.com

**OXXT** · #6 18 Jan 2003

Sorry bout that Grant I recently changed my email. Thanks for letting us know. Seems simple enough replacing the gasket.

Would you normally use a sealent as well as gasket or install it dry??

Thanx