Oil pan replacement Question

This morning on my way to work a big rock jumped out in front of me and my FJR. I escaped any injury, but the bike wasn't so lucky. I have a bent front rim and I punctured the oil pan on the front right corner. I work in a machine shop and am betting that I can repair the pan with a little help from the welder, but I wonder if any of you would like to opine on the R+R of the pan. I have the plastic off and am checking it out right now. It looks like the removal of the pan will require me to remove the exhaust system and then the pan should come off pretty easily.

Anyone care to burst my bubble? Is there anything about this job that I am not seeing? I would appreciate any insight that will keep me from getting the thing half way apart only to discover I am in way over my head. I am not a mechanic, but I can handle myself ok around this stuff and have been doing my own wrenching for a long time. Is there something that is going to spring apart and make me wish I had left it to the pros?

Thanks in advance guys

Tom

An '05 owner holed his oil pan on the Haul Road in Alaska last year. I don't remember him saying there was a big issue removing it. He had it welded...and even added a protector at the same time....and then proceeded to ride non-stop across North America.

We had another holed oil pan that was beyond repair at NAFO. Dealer replaced the oil pan on a Saturday...so leads me to believe it's about cowling and dropping the header.

But, I only slept at a Holiday Inn last night. Somebody will be along to burst my bubble or say yea verily.

Same thing happened to me only I missed the front tire but took out the oil pan as well. To replace the oil pan you will need

1. New header gaskets (4)

2. New Oil pan gasket (1)

To get to the headers is a PITA. I used an allen socket with a 6mm wrench to take off the nuts holding the headers on. I only loosened the bottom of the radiator. I couldnt figure out how to completely remove the radiator. Pull off the cans and the bolt holding on the CATs and the whole exhaust comes off. After that there are about 15 allen type screws holding the pan on. (DO NOT FORGET TO REMOVE THE ONE IN THE MIDDLE OF THE PAN, IT IS RECESSED.) I missed that one screw and almost really screwed things up. Once all the screws are off the pan comes right off. Just put the new gasket and pan together and reverse the process. This is an all day adventure just because of the headers. There isnt a lot of space. Also, all of the allen screws dont need a lot of torque to be tight. Same goes for the screws that hold the headers on.

Hope that helps.

Slappy said:

Same thing happened to me only I missed the front tire but took out the oil pan as well. To replace the oil pan you will need1. New header gaskets (4)

2. New Oil pan gasket (1)

To get to the headers is a PITA. I used an allen socket with a 6mm wrench to take off the nuts holding the headers on. I only loosened the bottom of the radiator. I couldnt figure out how to completely remove the radiator. Pull off the cans and the bolt holding on the CATs and the whole exhaust comes off. After that there are about 15 allen type screws holding the pan on. (DO NOT FORGET TO REMOVE THE ONE IN THE MIDDLE OF THE PAN, IT IS RECESSED.) I missed that one screw and almost really screwed things up. Once all the screws are off the pan comes right off. Just put the new gasket and pan together and reverse the process. This is an all day adventure just because of the headers. There isnt a lot of space. Also, all of the allen screws dont need a lot of torque to be tight. Same goes for the screws that hold the headers on.

Hope that helps.

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wow.

Slappy said:

Same thing happened to me only I missed the front tire but took out the oil pan as well. To replace the oil pan you will need1. New header gaskets (4)

2. New Oil pan gasket (1)

To get to the headers is a PITA. I used an allen socket with a 6mm wrench to take off the nuts holding the headers on. I only loosened the bottom of the radiator. I couldnt figure out how to completely remove the radiator. Pull off the cans and the bolt holding on the CATs and the whole exhaust comes off. After that there are about 15 allen type screws holding the pan on. (DO NOT FORGET TO REMOVE THE ONE IN THE MIDDLE OF THE PAN, IT IS RECESSED.) I missed that one screw and almost really screwed things up. Once all the screws are off the pan comes right off. Just put the new gasket and pan together and reverse the process. This is an all day adventure just because of the headers. There isnt a lot of space. Also, all of the allen screws dont need a lot of torque to be tight. Same goes for the screws that hold the headers on.

Hope that helps.

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The whole evolution takes about 2 hours taking your time. Had the end of cahin binder go through mine.

I haven't had the oil pan off, but I have swapped the header out for a Muzzy. It's not the big of a deal. I even reused the exhaust header gaskets. It is a good idea to put a piece of corrugated cardboard over the back of the radiator so you don't damage it.

Thanks for all your help guys. I have the header off and all the bolts loose from the pan. Not too bad a job I guess, I just don't want to mess this up.

There is a plug thingy held on by 2 bolts located at the front left corner of the pan. It has a wire going to it. I have removed the 2 bolts and it doesn't want to come out. Can anyone tell me what that is, and how to get it out? :dribble:

07fjrTom said:

Thanks for all your help guys. I have the header off and all the bolts loose from the pan. Not too bad a job I guess, I just don't want to mess this up.
There is a plug thingy held on by 2 bolts located at the front left corner of the pan. It has a wire going to it. I have removed the 2 bolts and it doesn't want to come out. Can anyone tell me what that is, and how to get it out? :dribble:

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https://fiche.ronayers.com/Index.cfm/Module...NKCASE_COVER_1_

I think this is the page you want to check but can't be sure because this POS Apple iPone does not support Java, thanks to Steve Jobbs control freqick A-hole.

JamesK missed the link due to Steve Jobs' inconsideration.

Picture of the oil pan HERE but I don't see any kind of sensor/wire combo in the parts fiche.

Anyone???

You guys are awesome, and I appreciate your help. I still don't know what the "thingy" is but I did get it apart by dropping the pan and pushing it through from the inside. That's the good news. The bad news is that the pan is damaged pretty badly and even the bottom of the case is bent slightly. The bolt thru the pan in the corner where the rock hit was bent when I unscrewed it. I was on the fence as to whether I would file an insurance claim for this. I thought I could just weld up the pan and throw it back together and leave the insurance company out of it so as to avoid any rate increases, but now am questioning my thinking. I have a front rim that needs replacing, and a right lower fairing panel that is badly scratched, and has a hole in it, and an oil pan that probably could be welded, but probably should be replaced.

This bums me out greatly. Has any of you ever straightened an aluminum rim with any success? Does anyone know of someplace in the phoenix area that can do this? It is still holding air but is visibly bent and I have no idea if it still runs true or not. How about getting a used one somewhere? I looked on Ebay and found a couple of older ones, but nothing for my year of bike. A new one is $660. I haven't priced the plastic yet, but I gotta believe it's at least a few hundred bucks.

This is most likely boring the **** out of you all, but it's the closest thing to a wrecked bike I've had to deal with in the 25 yrs I've been riding. I guess I should consider myself lucky, but I am more that a little freaked out about handing my bike over to a shop and being without it for god knows how long, and fighting with the insurance co. over how or if it should be fixed. Feel free to kick my ass over this and let me know how you would handle it.

Thanks to all who chimed in and offered help on this.

Tom

07fjrTom said:

You guys are awesome, and I appreciate your help. I still don't know what the "thingy" is but I did get it apart by dropping the pan and pushing it through from the inside. That's the good news. The bad news is that the pan is damaged pretty badly and even the bottom of the case is bent slightly. The bolt thru the pan in the corner where the rock hit was bent when I unscrewed it. I was on the fence as to whether I would file an insurance claim for this. I thought I could just weld up the pan and throw it back together and leave the insurance company out of it so as to avoid any rate increases, but now am questioning my thinking. I have a front rim that needs replacing, and a right lower fairing panel that is badly scratched, and has a hole in it, and an oil pan that probably could be welded, but probably should be replaced.
This bums me out greatly. Has any of you ever straightened an aluminum rim with any success? Does anyone know of someplace in the phoenix area that can do this? It is still holding air but is visibly bent and I have no idea if it still runs true or not. How about getting a used one somewhere? I looked on Ebay and found a couple of older ones, but nothing for my year of bike. A new one is $660. I haven't priced the plastic yet, but I gotta believe it's at least a few hundred bucks.

This is most likely boring the **** out of you all, but it's the closest thing to a wrecked bike I've had to deal with in the 25 yrs I've been riding. I guess I should consider myself lucky, but I am more that a little freaked out about handing my bike over to a shop and being without it for god knows how long, and fighting with the insurance co. over how or if it should be fixed. Feel free to kick my ass over this and let me know how you would handle it.

Thanks to all who chimed in and offered help on this.

Tom

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all told you are talking about $2000 damage. You could install all of hte pieces and save the difference for farkling. It be coverd under comp since it was something laying in the road and not a collision, which should not jack your rates.

I had awrench go through my pan, and damage both lower fairings. I replaced the pan and kept the fairings in the box in case I needed them in the future. There are companies that specialize in fixing wheels. I would make the insurance company get you a new one and send the old one out to be repaired.

AuburnFJR said:

I would make the insurance company get you a new one and send the old one out to be repaired.

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Gunny woof! Let your insurance company pick up the tab. The wheel IS expensive. The oil pan is like $170, so that's not all that much, but once you add in the plastic, you are swiftly approaching $2k like AuburnFJR opined.

Let "The Company" give you back some of the money you've been giving them, get the bike fixed and let's ride!

Thanks fellas. You are speaking my language. I think I will call the ins co and see if they will send an adjuster to my house and just cut me a check for the damages and I can do the work myself. I hate to admit such ignorance as to how things like this work, but I have always taken care of repairs myself and have zero experience with the system.

I have the good fortune of having a spare bike to ride so I guess I will be counting my blessings and rolling through this. Thanks for letting me sound it all out on you all.

:yahoo:

Make sure you look very closely at the case where it is bent. You may have an oil leak if the pan and gasket don't fit properly. There could also be a crack where it is bent. At the very least you should point this out to the insurance adjuster. Even if you don't want to repair the case, the insurance may pay for it.

07fjrTom said:

Thanks fellas. You are speaking my language. I think I will call the ins co and see if they will send an adjuster to my house and just cut me a check for the damages and I can do the work myself. I hate to admit such ignorance as to how things like this work, but I have always taken care of repairs myself and have zero experience with the system.
I have the good fortune of having a spare bike to ride so I guess I will be counting my blessings and rolling through this. Thanks for letting me sound it all out on you all.

:yahoo:

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Also, take it to the dealer and get them to give you an estimate of the repairs. There may be things that you don't see that are damaged too. Also it helps prevent the insurance company from low-balling you

AuburnFJR said:

07fjrTom said:

Thanks fellas. You are speaking my language. I think I will call the ins co and see if they will send an adjuster to my house and just cut me a check for the damages and I can do the work myself. I hate to admit such ignorance as to how things like this work, but I have always taken care of repairs myself and have zero experience with the system.
I have the good fortune of having a spare bike to ride so I guess I will be counting my blessings and rolling through this. Thanks for letting me sound it all out on you all.

:yahoo:

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Also, take it to the dealer and get them to give you an estimate of the repairs. There may be things that you don't see that are damaged too. Also it helps prevent the insurance company from low-balling you

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+1, I had a low speed T-bone with another bike and I stayed up ,the other bike totaled, I did not think my bike was too bad, $2-3k at the most

I took it into the dealer and it came to $7,500. His insurance paid it.

Since this insurance claim should fall under "comprehensive" (vice "collision"), you should not see any rate increase unless you have a real POS insurance company.

Hitting road debris, getting a windshield rock crack, even deer-strikes... all should fall under the "comprehensive" umbrella.

07fjrTom said:

Has any of you ever straightened an aluminum rim with any success? Does anyone know of someplace in the phoenix area that can do this?

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Back in '06 I had a bent Corvette rim straightened after the GF kissed a curb with it. Wheel Specialists in Tempe did the work for $60. Wouldn't hurt to give them a call and see if they work on moto rims.

I remember seeing a post by HaulinAshe a while back in which he listed one or two comapnies who specialize in MC rim repairs, one is based in NC if I rememember correctly. Do a Google search and you'll find it.