Emptying the Crankcase

Remove, label, and store the crossover tube. As you do so, check the condition of its two O-rings--replace as needed.

Remove the crank assembly. It must be lifted out squarely, so as to clear its bearing without binding. The assembly weighs over 50 lbs, so be careful of your back, your toes, the crank assembly, and other parts. This takes some strength as well as care and finesse.

If the cases will be separated long enough for any dust to settle (a few days or more, under normal conditions), wrap, label, and store the crank assembly.

If you have disassembled the generator area, you can now pull out the generator shaft and gear.

Wrap, label, and store the generator shaft, as you did the crank assembly. See photo below.

Next, remove the oil pump. To do this, you must take off the oil pump strainer (two brass colored screws on top of the oil pump). This will reveal a bolt hidden underneath. See photo below.

Be very careful of the screen on the strainer. It is a little delicate. See photo above. Then wrap, label, and store the entire pump assembly--with its bolts re-inserted in their places in the pump.

Now for the transmission. Unless you plan on doing some work on it, I'd suggest you pull the entire thing out, as a single unit. Here's how I did this.

First I used a few big wire-ties to lasso the pieces together. See photo below.

Next, I tilted the case up, on edge. Then I wiggled the transmission shafts--all five of them--out from the case. The shift-fork shafts can slide out of the forks at any time, so keep everything together by holding the transmission roughly horizontal.

Once the transmission is out of the case, be sure to cinch the wire-ties a little more. Then wrap, label, and store the assembly. To see my wrapping job, see the photo shown earlier in this section.

To access related articles, refer back to the Complete Engine Tear Down, Orientation article in this series to see which additional articles best address your situation.

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DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only.  Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure.  You assume all risks associated with the use of this information.  NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.  Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.

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