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The first step is to
drain the oil. The
engine doesn't need to
be warm because you will
be removing the old sump
so any dirt or debris
that has settled out
will come out anyway.
If you can SAFELY
elevate the bike so that
you can get your head
under the engine while
working, the job will be
much easier. It's
somewhat tedious to work
via a mirror for most
people (see below for
where a mirror can come
in handy). But be
careful - if this bike
falls on you the result
can be just as fatal as
a falling car.
Once the oil is
drained and you have the
bike positioned, remove
all of the 10mm bolts
around the edges of the
old sump. Once you make
sure all the bolts are
out you should be able
to work the old sump off
of the engine. You can
use a soft drift or
block of wood and a
hammer to dislodge it.
Now that you have the
old sump removed, clean
the bottom of the engine
crankcase where the new
gasket will go. Brake
cleaner works well to
remove any remaining
oily residue. Be careful
not to gouge the
crankcase surface while
cleaning it or you may
develop a leak.
You will see the oil
pump on the left side of
the engine crankcase
facing the front of the
bike. It has a round
screen on it that is
held in place with wire.
The wire goes through a
hole in each of the 2
'pins' that stick
through the screen.
First, remove this wire
and then remove the
screen.
The oil pump pickup
extension has a new
screen welded in place.
This screen must be
installed in place of
the one that you
removed. The tricky part
of installing the screen
is getting the new wire
through the holes in the
pins from underneath.
You'll need some
needle-nosed pliers and
a bit of patience. It's
not a hard job, just
trying. If you can't
elevate the bike safely,
this is where you will
need a mirror to see
inside the pickup to
thread the wires through
the holes.
NOTE: Do NOT
rotate the pins to
adjust the angle of the
holes - these are also
the end cap bolts for
the oil pump. If the end
cap is too tight, the
oil pump can seize.
Once you have the
wire safely in place and
the ends twisted
together to lock it in
place, you are ready to
install the new sump.
Make sure the gasket
surface is clean, and
recheck the crankcase as
oil often 'wicks' out
onto the mating surface
so it may need a last
spray of cleaner. Do a
test fit to make sure
everything lines up and
to make sure you have a
feel for the fit.
Use the gasket cement
of your choice. Some
prefer no cement, others
like the traditional
shellac based gasket
sealant, and others RTV
silicone. Whatever you
use, don't overdo. In
this case the minimum to
do the job is best. I
like to put a bit of
silicone between thumb
and forefinger and wipe
it onto the gasket.
Get everything in
position and raise the
sump to the crankcase.
Get one of the bolts
started and
finger-tighten it enough
to stay put. Next, start
another bolt on the
opposite side to help
guide the pan. It's
better to tighten the
bolts on alternate sides
than to go in a circle
because it doesn't tend
to 'walk' the gasket. A
good pattern to use is
to start with a center
bolt on the right side,
then go to the opposite
bolt on the left. Return
to the right and do the
next bolt forward, but
on the left do one bolt
BACK. A hand nut-runner
is a good tool to use,
but avoid the powered
ones.
Once you have been
all the way around,
repeat the process
several times. Each time
you will find that the
sump has settled a bit -
the cork gasket used is
especially flexible and
is intended to compress
a lot to seal well. If
you only go around the
sump once or twice,
you'll find the bolts
somewhat loose by the
next oil change.
Cup a 1/4" drive
ratchet in the palm of
your hand and tighten
all bolts equally,
following the same
pattern as above. Over
tightening can strip the
threads.
Give the gasket
cement some curing time.
Make sure the drain plug
is in tight and fill
with fresh oil.
NOTE: The
dipstick will NOT
register the first quart
of oil. Don't forget to
allow for the extra
capacity when changing
the oil.
Now ride that puppy!
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