I think i might have messed up.....

[iman501]

Alright guys, i went to change my transmission's oil today. I drained it, and went to remove the inspection cover to refill it again. I got the top torx bolt out just fine, well when i went to remove the other two they were pretty stripped, and i guess over time they got stuck in the case as well. I tried to get them out with a cold chisel and spinning them using a punch and small hammer as well. None of this broke the bolts free, and i really really dont want to drill them out.

well next i figured i might as well remove the whole case cover and put some penetrating oil on the inspection cover and let it sit over night. I could use a new gasket anyway.

i skimmed over a thread i found using Google on how to split the case. I thought it sounded pretty straight forward so i went ahead and removed all the allen bolts shifter linkage and such, and figured it'd pop off with a little mallet work.....

It didnt just pop off.

At this point i actually got on my computer and pulled up the manual. In the directions by the book it says do all the stuff i did, along with removing the inspection cover and something about the hook and ramp for the clutch....

I've now screwed myself and need to replace the gasket for sure due to loosening the case enough, and ruining the gasket. I need help figuring out how to actually get my case off. keep in mind i cant get the inspection cover off due to two of the three torx screws being stripped...

 

[GAXB9R]

I know you said you didnt want to but go ahead and drill the heads of the inspection cover bolts off. There bolts from dealer are a lot cheaper than really messing something up. When you drill the heads off the bolts the cover should pop out I you hold your mouth right. Then you can really see what's going on with them. Did you change it before or ever had it opened. Are out the original owner? If not they may have used lock tight and the. You stripped it out trying to get them somehow. Just thinking of different scenarios. Take your time with it. You will get it[cool]

 

[JOEL9]

Your clutch cable goes through the primary cover and hooks to the ball/ramp assy. on the clutch. you kinda need to get that inspection off to un-hook the clutch cable to remove the primary cover. better drill them out, gonna have to anyways at this point.

 

[iman501]

I've had the inspection cover off before yes. But never the entire case, i Dont remember stripping the inspection cover screws last time though?....

But like i said i've already semi separated the case. enough to allow the gasket to break free, and i can already tell that there is no chance of reusing it. So I am going to have to get the case off regardless now. and once i do i will hopefully be able to break the torx bolts for the inspection cover free after some time with penetrating oil.

My issue and question right now is, do i actually have to remove the inspection cover to split the case? or can i get it apart with leaving the inspection cover in place where it is?

i am not the original owner of it, i think i'm # 3 so as far as having the case actually off before i couldnt tell you?.......

 

[iman501]

sorry Joel, i was typing while you posted i guess haha. But i figured that would be the answer i got from asking this question.....

oh well guess i'll have enough work to do tomorrow i guess....

So Like i said above, i've never actually split the case before, and am unsure of the owners before me. Besides replacing the gasket, what other stuff should i replace/check for while i have the case off?....

 

[wolfo68]

you need to be able to unhook the clutch cable to take the primary cover off. those bolts are cheaper than having to replace the whole primary cover.

 

[JOEL9]

really nothing to replace except for the gaskets (primary, inspection cover). you will probably have to adjust the primary chain also after re-assembly. you really need a service manual to help you out. don't let all this spook you though, it's all pretty straight forward.

 

[iman501]

i have a digital copy of the service manual here on my computer. (when i said i googled a thread to learn how first, i was on my phone)

and hopefully all goes well now..... I just placed my order for a new gasket for both the case, and the inspection cover, I'll see about getting everything apart tomorrow, and hopefully by monday at the latest i can get everything back together.

 

[JOEL9]

Cool iman, keep us posted[up]

 

[GAXB9R]

When you do drill the heads off be careful not to drill on the case. You dont want to end up going through it. Hope it works for ya.

 

[cgo]

Keep in mind, splitting the cases is not the same as removing the primary cover. You're not splitting the engine case in two, you're actually trying to remove the primary case cover and inspection cover. If you had to get to the internals of the bottom end, you'd need to split the case. Just semantics so we're all on the same page.

To remove the primary cover, you need to take the clutch cable off the outer clutch ramp. It's not hard, but you need to get to it from the inspection cover as others have stated.

 

[iman501]

cgo is right. its just the cover.

but i went agead and drilled out the bolts, they came out eventually just took my time with it, and no damae to the case was done. I'm now waiting for my new gaskets to arive in the mail. i got bored this afternoon and took my exhaust off as well, i'm going to paint it black tomorrow with some high temp paint.

as far as getting the clutch and cover back on and together its just the inverse of what i did, and make sure i have a good amount of tension on the chain right?

 

[RT Performance]

That chain needs slack about 3/4 of a I change play.
That's what the small window is four

 

[GAXB9R]

Glad to hear you got it off with no further problems.[up]

 

[nikfleisch]

Keep us posted. [up]

 

[iman501]

about 3/4 of a I change play.

what do you mean by that?...

I'm still waiting on it to arrive in the mail. I hope it gets here Monday, because Tuesday i have to stand duty on the boat (coast guard) and then we get underway on Wednesday for like 8 days.....

 

[iman501]

^^^????

 

[konarider94]

you check this through the inspection hole that has 2 bolts holding the cover on.

 

[iman501]

alright guys, got back from underway, and got the bike back together. i got the case and gasket on without much trouble, then i went to take off the inspection cover to check my primary chain.....and guess what....

yup those two bolts were siezed up to. I sprayed it with some pb blaster and let it sit for about over night, but it didnt make much differance. So i went ahead and drilled those out as well. They came off easily. i tightened up my chain a bit, and replaced the bolts with alen heads.

besides all that i did paint the exhaust black, so i put that back on, and i changed the spark plugs as well.

overall it was a learning process, but i'm just glad its all back together. I took it about two miles down the road and back to test it all, and it seemed to run just fine. I'm about to head into town so itll get a good 40 miles put on it tonight to really see how she does.

Thanks for all your help guys!!! you all rock!!!

 

[Lando]

If I were you, I'd go ahead and put some antiseize on those new bolts, and not over tighten them.