Re: Diablo Shop 503
Posted: Fri Dec 31, 2021 10:32 am
The typical upper aluminum spacer is just straight. If you have not noticed by now, there is no seal in this area. Another potential problem is if your E-clip ever pops off your secondary clutch while you are out on the trail, the clutch slides off the shaft slightly and this allows the top gear to fall off the splines and there you sit.
I had a few spacers made up with a shoulder on them. In theory, this should leak less oil and if the E-clip does come off, the shoulder should hold the upper gear on the spline. Pretty neat idea I think.
. . .
Place your upper spacer on the shaft so the upper cover goes on in the proper location. Use a thin cork gasket so when the bottom cover is installed, the seal is on the lower sprocket seal area as needed. Place a bead of RTV on the housing putting a slightly thicker bead on the bottom circle.
. .
Put the gasket in place and add another bead of RTV again with slightly more sealant on the bottom circle.
. .
Put your top cover on and put some of the cover bolts in place without tightening them too much. Put a fairly heavy bead of RTV on the surface where the bottom cover overlaps the top cover.
. .
Put the bottom cover on being careful not to damage the seal. Put the rest of the cover bolts on and just snug them up for now. Let the gearbox sit for a couple of hours to let the RTV set up and tighten the cover bolts.
I had a few spacers made up with a shoulder on them. In theory, this should leak less oil and if the E-clip does come off, the shoulder should hold the upper gear on the spline. Pretty neat idea I think.
. . .
Place your upper spacer on the shaft so the upper cover goes on in the proper location. Use a thin cork gasket so when the bottom cover is installed, the seal is on the lower sprocket seal area as needed. Place a bead of RTV on the housing putting a slightly thicker bead on the bottom circle.
. .
Put the gasket in place and add another bead of RTV again with slightly more sealant on the bottom circle.
. .
Put your top cover on and put some of the cover bolts in place without tightening them too much. Put a fairly heavy bead of RTV on the surface where the bottom cover overlaps the top cover.
. .
Put the bottom cover on being careful not to damage the seal. Put the rest of the cover bolts on and just snug them up for now. Let the gearbox sit for a couple of hours to let the RTV set up and tighten the cover bolts.