It was time to enter the Burman GB gearbox of mystery, I have never talked to anyone that actually enjoys delving into a gearbox and I am the same really but it was time to see what lurked under the cover. Now the owner of the bike had told me he had never had any problems with the gearbox and sure enough before I removed the cover I managed to get all the gears and everything seemed fine "whoopee".
First job was to take the dirty gearbox to work and give it a damn good clean, that done I removed the outer cover and the first thing I noticed was there was no gasket (not that unusual on some older bikes) but there was a mountain of blue goo...as I have said before using goo is fine but go steady with it.
Apart from the build up of crud laying in the bottom there was nothing much wrong, no real signs of wear or damage so I inspected said crud for metal fragments and luckily it was just crud, happy days. Next I washed the whole gearbox out with Wurth Brake Cleaner until all the old oil and any remaining dirt had vanished, this is a great product for cleaning as it comes in a high pressure aerosol, shifts grease and grime easily and it evaporates very quickly so the item you are cleaning is dry again in minutes. I fitted a new gasket and put the outer cover back on and you will need the help of an octopus to do this, don't forget to tension the kickstart spring first. Once all that was done I refilled with gear oil and fitted the new filler cap and gasket, everything still works as it should so far, kickstart returns ok and I can get all 8 gears ha ha....job done.
I bought a new tab washer for the sprocket nut as there wasn't one on it, just in case you were wondering what was hanging on the shaft. Stay Tuned