I've bought a new inner clutch cover for my Beta Rev3. But the rubber padding between the engine and sump guard gets in the way of fiitting it. There looks tyo be two options, either (a) drop the sump guard off the bike, or ( cut some of the padding out and then push/glue it back in afterwards. I've heard that getting a sump guard back on can be a nightmare job. How do people refit these covers ?

take the sump guard off it will be easier in the long run

Yep sumpguard off is the only proper way to do it.

When you put the sump guard back on put the two back bolts in very loose and then put the bike on a stand of some sort to put the weight on the guard and flex it up to put in the two front bolts

I found that the only way to get the sump gaurd back on my old 2003 Beta was to :

1) put back bolts in but dont fully tighten down [try to get at least 5 threads into the nut so they can take serious load]

2) fit all the rubbers and ensure they are in correct place.

3) using a ratchet tie down strap round the frame, plus a length of 2"x2" wood between the strap and the front of the sump plate. pull the strap up as tight as possible till the front mounts are close enough to the frame to fit the bolts, if there is still too big a gap, then use the leverage on the 2x2 to further manipulate the front of the sump plate into the correct position.

4) tighten all bolts and jobs done.

If your sump gaurd is bent, this is the only way to get it on, and it becomes a one man job thanks to the ratchet strap.

Good luck

Edited March 10, 200818 yr by AMCQ46

....Or do what he said

Thanks,

I took the sump guard off....and it went back really easy !

Just need to suss out which coolant to use to avoid the problem happening again !

Cheers

which coolant did you go for , and was your original problem corroded inside water pump housing.

was it a straight foward job getting clutch off, and did you renew all seals? I assume there is no need to take engine out?

as you can guess I am about to refit a new case when i order it i would like to make sure i have all the bits needed to refit in one go, would you mind listing all the bits needed please.

Edited March 24, 200818 yr by tilertrialler