[SurfinCR]

same thing i ran into and am about to do tonight you have to take the head off.found that out the hard way also.

[floxera]

I too dreamed of splitting the case from the bottom to replace second gear.

I ended up replacing the whole engine it was cheaper and easier.

[Mr. Clean]

Yeah go back and read that manual again. You have to remove the head and jugs in order to split the cases. You also need to remove the clutch and starter gear as well.

[SVTim]

The topend has to come off to split the case. According to haynes and clymer manuals.

Sorry for resurrecting an old thread, but this is an update on the issue...

For all of those who thought and/or said the head and jugs needed to come off in order to get the lower cases off, is wrong! After removing the clutch basket, there were a few more bolts hidden in there. As soon as we got those bolts out, the lower case came right off!

We have the new transmission installed, the engine completely back together with all new gaskets, and the engine is mounted back in the bike. Now we have a few more hours worth of work and we should be done.

I will update this thread again with a link to my website with more pictures than imaginable documenting the process.

[ThAzKat]

well thanks for putting us in check bro, just kidding. I am happy you got the cases apart, FINALLY.

[Mr. Clean]

I'm not sure how you did that, but congratulations. I've only torn about a dozen of these engines apart so what would I know?

[ThAzKat]

I'm not sure how you did that, but congratulations. I've only torn about a dozen of these engines apart so what would I know?

not a damn thing obviously, I had to say it before Lou did

[floxera]

That's awsome. Can't wait to see the pics/how-to.

[SweetLou]

Not a Damn THing!!!

[SVTim]

Well, I finally got the gallery working on my web site and posted all of the pictures. They are available here: http://www.timgajewski.net/gallery/transwapkat. There are 88, with some accurate captions.

[Anonymous]

GUYS, (AND GALS)

This is my bike that was fixed, and SVTim offered up his garage to do it. The story behind it is a 10.50 tranny from a 97 kat off of ebay, which was in incredible shape. Total cost of project was less than 250 dollars, and that included grinding and painting headers/exhaust, and battery tray. Other than that, a pissed off wife, and a bunch of time. But as of now, I am going for inspection tomorrow, and she runs great....

Can't wait to get on the road...
Check out tim's site...Im the moron in the green flannel putting the clutch back together...
Enjoy
Dave

[Anonymous]

Well, I finally got the gallery working on my web site and posted all of the pictures. They are available here: http://www.timgajewski.net/gallery/transwapkat. There are 88, with some accurate captions.

Dude! that was awesome! thanks for the view!

[ThAzKat]

great pics, I looked through them thoroughly due to the fact that mine is a pre98. I am concerned that there is possibly some small fragments in the engine and why I said to take the whole thing apart. I think she looks awesome and a fine job bro. I have to say, "Three men and a BEER"

[SVTim]

I would have loved to have taken everything apart, however, we got started later in the winter and didn't the money.

Yeah, those pictures don't show the full beer story though :P.

[md86]

Wow , in that pic on the third page with the "pieces of metal found tin the oil pan" , one of those pieces looks EXACTLY like the piece I found when I dropped my oil pan a couple years ago . Looks kinda like part of a gear or something . I actually kept the part for some reason !