Originally Posted by bikerfish
had a guy at a rally snap a shift spring, a buddy and I had his tranny out in about 20-25 minutes, including beer breaks, we simply picked a side and went to work. Guy at the rally had a workshop trailer set up, had a spring, replaced it while we had dinner, then it went back in the bike, that might of took an hour, many more beer breaks! next morning the guy rode the bike home with no troubles. heck, we even greased the splines!!
yep, we slid the swingarm back, I always carry the socket to fit the swingarm nuts.
Make very, very sure your breather bolt is clear.
If the cover is so warped it won't seal, then what you think you are getting for your shimming might not be what you are actually getting. So evaluating cover flatness would be next. Ditto case rim flatness. One game is to remove the gasket, clean things up, then put a gasket thickness shim washer (mic. the outgoing gasket) at each of the bolts, put cover on and torque lightly, then go around and check the gap with feeler gauges.
When I had my 4 speed gone through by a pro, it came back with ample evidence of sealant at the rear cover. Something brown. So the guy wasn't the neatest with the sealant, his tranny work is unquestionable. If he's using a sealant, he knows something. For myself, when in doubt, I glue the crap out of everything. the Ultra- series silicones work very well and can be used a number of ways---on very clean metal for adhesion or on oiled/waxed/silicone greased metal for a non-adhering gasket. There are also games that involve assembling the parts on the wet silicone, barely tightening them. Allowing the silicone to set overnight and then torquing fully. This works very well on rocker covers. For your application you need to go super thin so I would use a sealant on a clean surface and plan on it adhering.