Pulled the box out and found the following:-

The tops of the teeth of the water pump gear were floating around in the oil, but none in the actual gear box. These had been sheared off but the pump still works ok when the gear is engaged properly.

No thrust washer on the water pump shaft, no suprises there.

The circlip on the selector shaft wasnt located in its groove, making the shaft have a lot of lateral float.

All thrust washers and circlips in the box were present and correct with nothing obviously amiss in there.

The box isnt back in the bike while I wait for parts, so I dont know if it is fixed yet, but the bits of plastic sheared from the pump and the selector shaft circlip may have been causing some problems.

One small thing that I am mad with myself is I broke one of the webs between the tangs on the clutch basket when my locking tool slipped. It took two of us to remove the nut, one holding the locking tool and the other swinging on a breaker bar. That nut must have been put on by a gorilla, because it took one to get it off, the rattle gun wouldnt touch it.

Do you think that the basket is still OK to use as the web couldnt be providing any real strength to the basket?

Should get a chance at the weekend to put every thing back together, so I will know then if things have improved.
_________________
Russ

MC21SP