Well, it was fun while it lasted?!

[turbojonn]

Got the bike back on the road with a fresh head, pistons, and cylinder. Makes loads of power. Yesterday I was pinning it in fourth and it was really pulling when it jerked and went "clunk clunk" and I could feel the chain and back wheel react. I yanked the clutch in. It clunked again as I was letting off and then acted normal on the very SLOW and easy ride home. I think the tranny is not up to the job. It's a stock tranny.
I'm making less thsn 200 hp, which I understand is the limit for a heliclal set up (the basket has a heavy duty backing plate that's welded on). I checked the basket, it was a bit loose at the rivets, chain was tight, sprocket tight too. I'll need to get the basket redone as I'm sure it's suppose to have zero wiggle between the backing and the basket (?).

Can I access the tranny via pulling the lower half if the cases off, as in flipping the engine upside down? Or do I have to fully dissassemble it?
Thanks in advance for any aadvice and insight.

[Steve]

I have never done it, but I understand that you CAN flip the engine and remove the lower half.

Keep in mind that there are a few hidden bolts that might make you think otherwise. I think one or two of them are in the starter cavity, so you do have to remove the starter.

.

[rapidray]

You can split the cases without even removing the valve cover. Pull the ignition plate, stator cover & clutch cover. Pull the clutch basket & 2 plates behind it that hold the case halves together. Remove the 'z' shaped plate on the left side, in front of the countershaft. Remove all the upper case bolts & don't forget the 2 by the starter. Flip the engine over, pull the oil pan & all the case bolts & the 1 nut & then you can pry the case halves apart. I can build you a clutch hub when you are ready too. Let me know if I can help. Call me if you need to.
Ray.

[turbojonn]

Thanks Ray! You single handedly make the GS community a better place. By the way, the pistons and cylinder are great.