Originally Posted by JohnA
I think I see now: So you're saying that the oil comes out of the hole in the crankcase that's behind the clutch drum, where the crossover shaft emerges before its 'U' piece? This hole should have an iron bush at each end - best to make sure these are in place.
So, after the oil has come out of this hole, it then finds its way out of the drain plug-hole (the plug from which you have removed), and from there splatters all over the place or forms a pool if you park the bike on the sidestand?
Well, no significant quantity of oil should get through that shaft bore. It shouldn't be above the level of the bore at the gearbox cover end, and the gearbox shouldn't build up enough pressure to force oil through what should be the very small gap between the shaft and the iron bushes.
Have you got no more than 500ml of EP90 gearbox oil in the box? Do you know whether those iron bushes are ok? There should be NO appreciable slop between the shaft and the bushes at either end.
If I've understood the problem correctly and if all the above is AOK, I'm certainly stuck for ideas!
Yes John, that's exactly it. Both iron bushes are in place and there's no freeplay between the shaft and bushes/hole. The addition of the o-ring and the primary cover to hold the foot change spindle in place worked about 50% better - still had oil that came out but not nearly as much as without the o-ring. However, noticed a little difficulty in shifting gears sometimes and then sometimes not...more in the down shift then anything. Maybe a thinner o-ring? I'll experiment...now that I'm a dry clutch, going into it without having to drain is so much nicer.