Question about 2000 Moto Guzzi Sport 1100 i

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Changing gearbox seals

Is it possible to change all the seals (gear shift

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Clutch pushrod and final driveshaft) without removing the gearbox/engine from the the frame? Just removing the swingarm and driveshaft to gain access. This is on a Sport 1100. Mine started leaking oil today and upon closer inspection all the seals look a bit suspect to me. The main offender being the drive shaft seal. Trying to chenge the rear seal with the box in-situ is fraught with problems. Apart from the accessibility issue it is difficult to get an sort of sel hook in to pry out the seal without damaging the face of the speedo drive worm that the seal runs on. Alo in many, many cases the leak isn't actually from the seal, what will cause it is the failure of the o-ring on the shaft beneath the hardened washer forward of the speedo worm. This is supposed to seal and prevent oil getting up the shaft between it and the worm and leaking out the back. In many many cases this will be the culprit rather than the seal itself and if only the seal is replaced the leak will continue. My advice would be to simply bite the bullet, pull the gearbox and go through it front to back re-sealing and oo-ringing as you go. You can also shim it up properly and check the clutch while its out. Yes it is a 'Big' ish job but its not one you're likely to need to do very often and at least you'll know it has been done right. ,,,

Posted on Nov 10, 2008

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The bike has a bent shift fork in the transmission. You describe the classic symptoms. The engine will have to come out of the frame. Then it gets flipped upside down, right and left side covers, shift shaft, and other components are removed, then the bottom half of the gearbox is removed. This allows access to the shift drum and shift forks. There are some special tools needed and I don't recommend a novice mechanic tackles the job. Below is a diagram of how the shift drum moves the shift forks left and right to make a slider gear engage different gears. Please rate my answer. Thanks. tombones49_116.gif

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The dogs do wear after high mileage which can make them slip out of gear
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You could get the gearbox 'blueprinted' (i.e. to manufacturers exact specifications) but this will cost a bomb !
Your best bet is to complain again & at least get a ride on another rocket3, or get it sorted under warranty

Ride safe
Please mark this as very helpful (if it has been!!)

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The clutch is not fully dis-engaging. That is what is causing the shifting problems. Hopefully a shift fork has not been bent in your efforts to shift gears. The cost of 6 or 7 quarts of oil and an oil filter is nothing next to the cost for replacing bent shift forks.

Please rate this solution. Thanks Coty!

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