I just pulled the alternator side cover to fix a small oil weep, and to check the pickup air gap. While in there, I removed the previously torn paper gasket (which was what was causing the leak in the first place), used Yamabond on the cover, and reintalled it.

Then, while reinstalling the shifter, I noticed the lever didn't auto-return anymore. It moved, but was stiff. I loosened the cover bolts around the shifter, and it moved properly again.

I asked my dealer, and he said the fix is easy: "just chuck it up in your Bridgeport and take 10/1,000ths off the boss on the cover". Well, I don't just happen to have a Bridgeport milling machine; anyone else ever run into this? My first thought is attack the boss with a die grinder, but I'm fighting the urge... Other thoughts, make a new gasket to return the spacing to OEM spec?

I have always cut a new gasket when refitting the cover.

It only takes about 5 minutes to cut one with good quality gasket paper. Just cut out the general shape wider than necessary by about 1cm on each side of the metal, with holes for protrusions so it will lie against the metal, tap down lightly with a piece of wood to get the picture, then secure it with nails in the screw holes, then tap around the edges with a piece of wood, and it cuts itself.

Makes a much better job than any goo.

Chris Kelly from California Cycle Works makes the gasket. 10 bucks maybe? I'll try to find the link in the am.

OK found it faster than I thought I would:

Aftermarket Maintenance Parts 15th item down.
http://www.ca-cycleworks.com/shop/catal ... maint.html

http://tinyurl.com/bqlaz

Why to make paper gasket, cause Ducati dealer sells good stuff(silicone) for that job and its quite cheap also? Need only to adjust again those pick ups, what can be easily made later, when covers are in they place. Pick up adjusting is critical, but easy job! Btw, all new Ducati engines have been made by using just that silicone, not any paper gasgets.... I dont need paper gaskets anymore, that Ducati stuff is very good!

fit and clearance. The sealant now used isn't thick enough.

I havent had any problems with that Ducati silicone..... all function, like should! But soon i must work with that "sprag clutch", so then i can see it again, how it function this time.... wondering little! :confused:

Finnpaso, you're right, the goo is usually sufficient. I have done it many times with my other Ducks. But with this particular Paso, there isn't enough clearance, and the shift shaft gets bound up on the case boss due to the lost thickness of the gasket.

Skins, John, thanks for the advice, I cut a new gasket and installed it last night, works well. Chris Kelley's doing right by us by providing gaskets that Ducati doesn't sell anymore, but I didn't want to have my motor disassembled for a week.

On a related topic, don't you hate when you take half an hour setting up and using a harmonic balancer puller to gently pull off your new baby's alternator cover, only to find some bozo has done the "screwdriver and ball pein hammer" trick? I understand that the Ducati Tool is pricey, but make your own, ferchrissakes!

:confused:

er, what's a harmonic balancer puller? sounds interesting ..

It has something to do with incense and crystals....

:laugh:

No, those are the Dilithium Crystals, they are contained in the heads of the 4v motors, I'm skeerd to touch 'em! I ain't skeerd uf nuttin in a 2v motor...

Here's my first attempt at a posting a pic, of a balance puller. They're $12 at Autozone:

Anyone interested in a pic of the "screwdriver and ball pein hammer" method?

Using the right tool for the job! That's no fun. Where your sense of adventure, your inner Rube Goldberg, be the bodger, feel the hammer. BTW you know how to spell pein! In that case it would be a pry-driver!

actually, i wouldn't mind knowing a bit more about the Dilithium Crystals ..