Oil Pan Mod by Ryan Werth
Tools Needed: 10mm 1/4 in drive socket
& short extension. Small snap-ring pliers. Pair of Pliers. 10mm end
wrench. 17mm 3/8 drive socket. 3 inch (76mm) long Drill bit size 3/16
(.1875) or (4.75mm .1870) 14mm 3/8 drive socket. Inch lbs. 3/8 drive torque
wrench. 3/8 to 1/4 inch reducer
extension.
Parts Required: Oil pan gasket. Washer .460 (11.7mm) diameter X .057
(1.44mm) thick. New oil filter. Five quarts of fresh oil. Possibly a sub oil
pan o-ring.
Begin by draining the engine oil and removing the oil filter. Remove lower
fairing. Remove the two oil cooler lines, only from the front of the oil
pan. Remove turbo oil feed line banjo 14mm bolt, it is directly under cooler
lines and will have a small screen inside it. DO NOT LOOSE this screen or
leave it off. You should have two crush washers for this banjo fitting, one
on each side of the banjo. You should have two small o-rings for the cooler
lines also. You do not need to remove the sub oil pan unless you want too or
it is leaking. Pinch & slide the two hose clamps on the turbo's oil
drain back hose and remove it.
Remove 15 bolts holding the oil pan on and remove the oil pan straight down,
it has a small vent pipe sticking up, do not bend it. Once oil pan is
removed immediately check for any large iron particles or
aluminum bits. You know what your looking for, anything other then oil
inside there is bad news.
Scrape old gasket off engine & oil pan, single edge razor blade works
good or medium file used lightly also removes small areas of gasket. Clean
oil pan in mineral sprits (solvent) wash solvent off with water and dry with
compressed air. Remove C-clip from oil pressure bypass and install washer
under it and install C-clip back in place. Locate the oil passage inside the
main oil feed line, it will run diagonal, actual drilling thickness is about
13mm or just over a half inch, be careful not to let the side of drill bit
eat into the side of the main oil mating surface and don't let drill bit
grab and go too far after drilling passage, threads for turbo's feed line
can be damaged.
Check oil pump inlet screen, clean if needed. Check all o-rings for cracks
& replace as nessassary. If your bike leaked oil from the turbo's inlet,
it could have been the vent pipe's come loose. Mine was, it can be tapped
back in place at this time also. If the sub oil pan is removed you can see
with a
light if the pipe is down all the way. Reinstall oil pan. Torque pan bolts
to 19 inch lbs. or however tight you put cam cover bolts. Make sure the
turbo's oil feed line banjo bolt has the
screen in place and it's clean. Install the turbo's oil return hose and
slide pinch clamps back in place. Make sure cooler line o-rings are in place
and when filling engine with oil, do not fill past the middle of the sight
glass when bike is level. Start engine & run for a few minutes and shut
off and recheck oil level. Look for oil leaks and make repairs before
riding.
