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A couple of pics with restoring the wiring harness, still in melbourne cant stop my head going back to the bike trying to plan next move when I return, first get cases and clutch back together , FCR'S? Then wiring harness I guess

Is that a stubbie of Coopers I see giving you a hand?

Cheers.

Nick.

Live next door to supercheap ? . I have some of their rolls of wire ..........and I aint buying any more . For something as short as a motorbike , I go to a car wreakers and buy ( sometimes they let me have it free if I get it out ) a whole ( or as much as I can ) wiring harness out of a car , and if you get the right one you get all sorts of colours and gauges, and the rear end harness is long enough to get round a bike , and if your real cunning you can often make use of existing plugs and connectors

Nick that's a coppers mild alright , love it, I'm sitting in a little pub in Melbourne right now having a pint of coppers pale ale , and mc tool that's a bloody great idea , for stocking the stores of auto electrical cable , will do thanks

Back to the bike, putting clutch side together and I found another problem with the clutch gear which has some scoring where the oil seal sits, I'm hoping this is not another sleeve or replace situation, would some loctite rescue this?

The scores are outside the seal so shouldn't be big issue but they could be filled with an epoxy metal then carefully rubbed flush.

Thanks I might try epoxy metal as if you look closely the scoring is right where the seal will sit

I have already got to this stage with new seal in but I think I really need to backtrack a little and sort this out ,it reeks of leaky rear mainseal syndrome

It aint pretty but not really a biggie . There will be enough contact between the seal and the gear so as to anchor it in good alignment so mechanical strength is not an issue but I would probly get a bit of something like Threebond in there ( wipe off the excess ) to fill the grooves just to be sure you have good sealing.
Looks like someone has bashed the bearing in with a small dia punch..........it would have to be a nice freshly ground one , pristine condition possibly , def well cared for .

Wahaha yeah mate I have to own up to that one, does look nice and fresh, now that's out the way you think some 3 bond let to dry and then seal or just smear on and bash the seal in

In the last pic I have ran some medium loctite on the scores and the seal edge and knocked
The seal in , good tight fit , maybe ok with the loctite ?

Depends on the Loctite you use. Not threadlocker. That's not a sealant. The only critical scratch could be the one that goes over the full width of the oil seal.
Threebond's probably also not ideal but it would work. You would put a thin film on the seal and then push it into position.
Is that a torn bolt stuck in the shaft?

I would use 3 bond but only because that's what I have at hand . Depends wether you want to actually repair the damage or just ensure a good seal.
Using some sort of epoxy I would remove the bearing and fill the grooves with whatever potion you choose and then partially refit the bearing , like so its flush with the gear , until the goo has set , then press the bearing fully home thus exposing some nicely filled grooves , and fit seal as normal

and next time you do something like that don't tell the world

I removed bearings and seal and will epoxy fill and sand before befitting all, thanks for all input