TS 150 GEARBOX OIL

[suzukix7]

I have put 500ml of gear box oil in my TS150 but it's still not coming out of the level hole?
The level screw is out of the casing !!! The bike is on axle stands with both wheels out but is level!!!
I am putting the oil in the right place aren't I guys. Removed rubber bung on top of clutch side casing behind tacho cable????

Dave

[Agronski]

You've definitely found the oil fill point - it really is that unsecured little rubber bung right behind the tacho drive so you can't get a decent funnel anywhere near it - wonderful DDR design

As for capacity - if you put 500ml in and doesn't come pouring out the check screw, either:
1 - it was completely empty and the gearbox was dry. Add a bit more and check if you can get it to overflow (I've had to fill my TS with about 800ml before and she was fine with it - makes less noise and the ride is smoother, but it's probably taxing the gears a bit...)
2 - The clutch-side gasket is dead and you're leaking a lot of gear oil. Try tilting the bike a bit and checking around the side-plate.
3 - The chain-side seals are gone and you're leaking gear oil into the space around the dynamo/chain - take the points cover off and check if the dynamo is covered in goop or there's oil nearby.
4 - If you've filled it, run it and then tried to drain it, maybe you're crankseals are shot and you're burning gear-oil. Check if your silencer/piston crown/spark plug are covered in oily black gunk. If they are, maybe time for some new seals.
5 - You've got a _serious_ crank-seal leak and your crankcase is now full of oil - take the head and cylinder off, and check that the crank isn't full of oil. If it is, DON'T TRY AND RUN IT, YOU'LL BUCKLE/SMASH YOUR CON-ROD.

Hopefully it's (1) and maybe (4) - but wouldn't hurt to check the others, just in case.
___

[suzukix7]

Hi thanks for the replies.

I checked it again this morning and its dribbling out fine now!!!!
Really strange cuz I left it a while to let the oil settle before panicking!!!!
Who knows!! I did turn the motor over with the kick start by hand first though to check!!

Dave

[therealche]

Ive had it many times! Fill gearbox with appropriate amount of oil... no oil from level screw. Add another 100 mls. still no oil. Add another 100ml and it starts coming out... and coming out, and coming out, and you end up with 250ml of oil in your drain tray.

[DAVID THOMPSON]

i think the word cling comes to mind,,pore oil in and it flows very slowly over everything..
and then finally comes out the other side ...

while your reading the book to see what you did wrong....



most often the wrong is not getting the catch pan in the correct spot...

dave

[therealche]

Yes, yes and yes Dave!