dabbist Posted January 31, 2016 Report Share Posted January 31, 2016 Hi All, Sorry if this has all been said before, but I couldn't find quite what's happening to me in any searches. I've just bought a 2006 Rev 3 200cc. It starts and runs delightfully, but going through the usual fluid changes before taking it out the gearbox oil clearly had a lot of water in it. I took off the water pump housing and impeller and it all looks stunningly nice and new. Having looked at a few more posts on similar topics the consensus seemed to be to change the oil, run it for a bit and then see what happens. So I changed the oil and had a play about for about two hours yesterday. I was a bit hamfisted filling it, so actually put in 700ccs of Putoline light gearbox oil, but when I dropped it out today I got 800ccs of nasty wet stuff. See pictures, The oil bottle's just there for comparison. To add to the confusion I went to top up the coolant and see how much was missing and couldn't get more than a drop into it. My reflex thought would be the water pump seal, but then I should be loosing water from the cooling circuit. Could that much have remained in the gearbox? It was warm when I drained it. I'd be most grateful for any bright ideas. Many thanks Quote Link to comment Share on other sites More sharing options...
pauls320 Posted January 31, 2016 Report Share Posted January 31, 2016 Got your seal in backwards... Quote Link to comment Share on other sites More sharing options...
worldtrialchamp Posted January 31, 2016 Report Share Posted January 31, 2016 (edited) gear oil contaminated with water/coolant will coagulate and the clumps tend to deposit in the upper reaches of the gearbox cavity making it awkard to flush. I've had to use other fluids in the box to completely fill it and slosh it around, drain it, filter the fluid, repeat process again. ...it takes very little water to change the appearance of the oil...also gets in through the gearbox breather hose Edited January 31, 2016 by worldtrialchamp Quote Link to comment Share on other sites More sharing options...
mspenz Posted January 31, 2016 Report Share Posted January 31, 2016 Got your seal in backwards... That's the one! Take the casing off and fit a new seal with the sealing lip towards the water side, also check the shaft to make sure that it isn't grooved and check the 2 small bearings while your in there. Good luck. Quote Link to comment Share on other sites More sharing options...
dabbist Posted January 31, 2016 Author Report Share Posted January 31, 2016 Thanks Chaps, That's great news. I've got the clutch out at the moment anyway (doing the mods) so I'll dig a bit deeper and sort that out as well. Thanks hugely for the fast response too. I wonder if I got a better price because the seller thought there was something drastic wrong with it. Cheers Quote Link to comment Share on other sites More sharing options...
mspenz Posted January 31, 2016 Report Share Posted January 31, 2016 Give it a good flush out in there, my bike came with a knackered seal and it's only running clear now...5 flushes later! Maybe worth doing a few flushes first with cheap thinner oil before using the good stuff? Mike. Quote Link to comment Share on other sites More sharing options...
p@ul250 Posted February 1, 2016 Report Share Posted February 1, 2016 Give it a good flush out in there, my bike came with a knackered seal and it's only running clear now...5 flushes later! Maybe worth doing a few flushes first with cheap thinner oil before using the good stuff? Mike. He's using Putoline light gear box oil. That is the cheap runny stuff. I'll only use Motul 300V 5W30 in my 300 Evo. Quote Link to comment Share on other sites More sharing options...
guys Posted February 1, 2016 Report Share Posted February 1, 2016 Nothing wrong with "light gear oil", it's recommended by Beta, Montesa and GasGas. But use the same oil for flushing as you're going to use for riding. 1 Quote Link to comment Share on other sites More sharing options...
dabbist Posted February 8, 2016 Author Report Share Posted February 8, 2016 Hi All, Thanks for the help and advice. I replaced the water pump seal (the shaft was fine) and then flushed the gearbox first with a mixture of cheap engine oil and paraffin then with gearbox oil and it came out absolutely "dry" both times. I did the clutch mods while I was at it and I have to say that I'm hugely impressed with the difference. The only bad news is that I discovered in the process that the bash plate was cracked through on one corner, so that's gone off to be welded and hopefully, once I persuade it back on, I'll be done with fettling for a while. 1 Quote Link to comment Share on other sites More sharing options...
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