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Join Date: Nov 2007
Location: Chandler, Arizona
I have had the front bevel gearcase off before, a few years ago. I found it difficult to reinstall with the engine in the frame, because there is a fairly strong spring behind it, and you have to push hard on it to force it back against the engine, line up the output shaft with the U-joint, line up the bolt holes, and hold the gasket in place, all with 2 hands. I ruined the first gasket, and had to get another new one. I used Permatex spray gasket tack on the last one, and it stayed in place. The gasket is really narrow in places, and is easily dislodged while dealing with the spring pressure and trying to get everything lined up at the same time. The only thing I would have done different as far as removing the engine is remove the front exhaust manifold.
If it will fit, a transmission jack might work well. I loaned mine to someone a long time ago, and never got it back. If the driveshaft disengages from the final drive while removing the engine, don't worry about it. I pulled mine out anyway to lube the rear splines. I did have the spring fall out of the coupler, I had to fish it out with a piece of clotheshanger wire. I put a lot of moly paste in the coupler, which held the spring in place while I reinstalled the shaft. If you remove the swing arm boot, make sure you reinstall it before putting the engine back. It has to go back on with the molded in numbers facing outside.
I am a motorcyclist, NOT a biker.
1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike