Factory Pro Shift Kit install- LONG read w/ lotsa pics

[Northwind]

You had to imagine the pointy arm

[DougZ]

Originally Posted by Northwind

You had to imagine the pointy arm

Oh, thanks for clearing that up....lmfao

[orangegilly]

Originally Posted by RIjon

Wondering if you need a gasket at all.....hrmz

I want to do this ASAP.

What's the secret fix for the clutch cover?

I thought about trying to re-use the stock gasket, but like northy said....it sacrificed itself for the good of my shifting.

As for the fix for a warped clutch cover, you tape or place a big piece of sandpaper to a flat surface, like my countertop (don't tell my wife... ). Then you basically sand off the warpage until the clutch cover is flat. If it's too warped, you need a new cover. According to Zoran, you don't want to pull the hole inserts out and shave them down (to put more pressure on the O-ring), as the tabs (being plastic) like to crack if you do this.

Rumor has it that Zoran has a few of these stock covers laying around (and one of them is on its way to Ohio).

Not all the covers warp, but they're prone to with exposure to heat and oil. Mine's a 2000 model, so the cover has had 7 years worth of heat cycles.

I did ride today, as I have just the slightest of seepage. The one thing I noticed almost immediately, is that I needed to change the timing of my shifting. I had to speed up my clutch hand, as the gears are available much sooner. It's almost like one motion now....before, it was clutch, shift, slight pause (to let the transmission actually engage the next gear), let clutch out. Now it's clutch, shift, let clutch out. If that makes any sense at all.

[orangegilly]

Well, I think I finally got the clutch cover sealed. I'll give it a good thrashing tomorrow, just to be sure. New O-ring, and sanded the cover flat. Slight seepage at first, but it's been 2 days since anything noticable.

[Northwind]

I just splatched Universal Blue all over the o-ring before I refitted it. But don't tell anyone.

[Maritan]

Next time, to remove those paper gaskets - try a gasket remover spray from Autozone or Checker's. That thing is REALLY vile - make sure you cover everything else from overspray. It eats paint - I know this for a fact.

[slakwhere]

Originally Posted by Maritan

Next time, to remove those paper gaskets - try a gasket remover spray from Autozone or Checker's. That thing is REALLY vile - make sure you cover everything else from overspray. It eats paint - I know this for a fact.

+1587662

that stuff is really really vile, but it does a superb job of getting the gasket off.

[orangegilly]

Well, the RTV sandwiched around the new gasket worked like a charm. Not even a hint of a leak, and I have no plans of taking it off again anytime soon.

[mstingray]

good stuff bro

[orangegilly]

Apparently, the mods found a way to resurrect this thread, but the links needed fixed to work with the new board. Updated the links, and it's all back to normal.

Thought I'd bump it up if anyone needs to do this this winter (*cough* wacky *cough*).