New oil seals for the gearbox cover

Outer cover comes straight off after removing the screws. No, nothing drops out on the floor.

While you might be able to machine the outer cover without stripping it down, I really wouldn't. It's not difficult.

Lip seals will no doubt be best, but quad rings are far better than o rings. Not considering them?

I agree with David, 

I have quad rings on my 650 and don't have any leaks from the shafts and there are lots of very happy riders who report the same.

No machining required either, so a quick and easy job to do. However, should you choose to renew/replace the gear change pawl and/or its spring while the cover is off, I'm sure you will soon get used to removing and replacing the cover to get the gearchange working properly again!

For info, I suggest that you leave the gear lever on whilst removing the casing as you can use it as something to pull the cover off with. Easy enough to remove it once the case is off.

Regards, George 

1. Study the parts diagrams on the Andover Norton website (and download a copy of the relevant parts book, easily found on the web)
2. Arm yourself with a copy of the Mick Hemmings gearbox DVD, available from the NOC shop.

George was a tad reticent with his comment about the gearbox fandango by forgetting to mention before you take the outer cover off engage second gear. When refitting clean the roller almost dry then daub with a thick grease. The rest as they say will become apparent as to the reasons why.

RGM sell the quad rings. I like to support our specialist suppliers even for things that are theoretically generic, but anyway it's mysteriously difficult to find selection boxes of quad rings as you can with o-rings.

Nah, pull it off in any gear you like.

I think Paul's idea is that it makes it easier to get the pin on the back of the ratchet plate, to push into the hole in the roller in the end of the quadrant arm when you come to put it back together.. Maybe it is. Not something that has ever troubled me.

Just make sure you cover the shaft splines with sticky tape so they don't cut the ring.

The kick start ring slot in mine is deeper than the ring size. I don't know why (previous restorer perhaps?). Anyway I had to fill the groove with silicone sealant before wriggling the ring in place and putting it back before the sealant set behind it. I've no idea if this is normal.