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Post by wardourdrive on Mar 19, 2007 12:22:00 GMT
As you will remember like a tw*t I cracked my oil sump.
I ahve now ordered a new sump with associated gaskets and O rings. Should be here on wednesday hopefully.
Now has anyone done this before on here.
From what I seein the manual I need to drain coolant and remove rad. Drain oil Remove exhaust then remove sump.
To make matters worse of course while I was syringing out some oil yesterday, too much went in when I was topping up the clear tube i was using dropped off in the filler cap and now has disappeared.
maybe I should just give up sell the REX and buy a push bike.
According to the man at Kawasaki Cutomer Care (he was pretty helpful) I should be able to get to it from the sump area. Tried to get the clutch cover off yesterday and it wouldn't budge. Any suggestions on this one.
I am having a bike nightmare and want to be back on the road for the weekend of course, especially with the trip to the ACE coming up on Sunday
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Post by firmhand on Mar 19, 2007 17:48:21 GMT
Your not the first, mate of mine rebuilt an LTD450 engine, stuck it back in the frame then some how managed to drop an allen key into the gearbox via the oil cap , he wasn't pleased to say the least . Just take it easy, one step at a time and don't overtighten anything mate!
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Post by wardourdrive on Mar 19, 2007 19:24:36 GMT
All ordered from Cradely Kawa. Very helpful chaps, in fact Peterborough Kawa also good. Can't moan all very helpful. Still none of them seem to have changed a sump before. Luckily Tom on the OC has and given me some tips. Well I am in trouble with the boss, too much spend on the rex but thats another thread I think. Oh well onwqrds I go. major issue if I can't get the tube out though, it could, slim change know of the chain in the clutch housing and cause all sorts of issues, mostly throwing us off I think. No tightening too much for sure. hopefully I will take pics each step of the way. Tom rekons 90 minutes to strip out and 3-4 hours to replace. Looks liek busy week for me then, certainly not all in one go.
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KES
Stuck in the saddle
Posts: 451
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Post by KES on Mar 20, 2007 7:33:54 GMT
If the clutch cover has never been before yes it can be tight .
Use a rubber mallet and tap the cover around the edges .
Note the word [glow=red,2,300]TAP[/glow]
On putting a new clutch gasket in cus if it aint been done before it will fall apart smear oil each side of the gasket, and the next time you drop half yer toolbox in their it will not tear .
Make sure you clean both mating surfaces with a stanley blade . Do not cut int it just like yer sraping paint after badly painting yer widow frame .
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Post by wardourdrive on Mar 20, 2007 13:42:13 GMT
looks like I wil be buying a rubber mallet to GENTLY TAP the cover then. New gasket on order of course.
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Post by kevrex on Mar 22, 2007 21:34:18 GMT
Let us know how it all goes si hope everything runs smooth for ya
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Post by wardourdrive on Mar 22, 2007 22:20:02 GMT
Sump back on and all torgued up nicely. Clutch cover No amount of tapping helped. F**Ck Off big allen key at the front prys point worked a treat . Over off, offending tube removed Took ages to getthe old crappy gasket off both mating edges. All done now, cover back on and torgued to 9.8 I have added 3 ltr of oil. should be 3.5ltr from dry but will do rest tomorrow. Big day tomorrow, zaust and rad back on. Hopefully test flight Saturday. Big thanks to all that gave advice, specially YOX and Burchy.
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Post by wardourdrive on Mar 23, 2007 10:55:23 GMT
Damn Ang tells me there is a drip coming from the front of the bike. Guess I am not finished yet. be I need to tighten something or have missed something major. Oh well back to the drawing board.
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Post by Renegade on Mar 25, 2007 8:15:23 GMT
Damn be I need to tighten something or have missed something major. You probably didn't tighten the bolts in sequence. And have probably crushed one side of the gasket.
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Post by wardourdrive on Mar 25, 2007 16:35:41 GMT
Ren even more basic than that. One of the oil lines connecting to the front of the sump has 2 washers and the other a big spacer and a washer. The one with 2 washers was dripping. Basically the washers had got stuck together so I was really missing a washer from the sump side. Fixed and all ok. Just got back fromt eh ACE so I know it is not leaking.
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Post by Renegade on Mar 25, 2007 20:43:49 GMT
Ren even more basic than that. One of the oil lines connecting to the front of the sump has 2 washers and the other a big spacer and a washer. The one with 2 washers was dripping. Basically the washers had got stuck together so I was really missing a washer from the sump side. Fixed and all ok. Just got back fromt eh ACE so I know it is not leaking. Glad it turned out ok
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KES
Stuck in the saddle
Posts: 451
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Post by KES on Apr 16, 2007 14:32:28 GMT
glad your sorted I only seen your pm today sorry
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Post by wardourdrive on Apr 16, 2007 19:18:34 GMT
glad your sorted I only seen your pm today sorry No problem, no oil is dripping out and I ahve done a few miles since fitting it
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