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Old 05-26-2016, 06:12 AM   #1
mayhem
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Default Crankcase Side Cover Gasket Replacement Questions...

I have a 99 Club DS with a FE290 that has blown the crankcase side cover gasket. Question is: Does the engine need to be removed for this repair? Which way is easier - in or out? Whats the best way to remove the engine? out the bottom or through the hole. Any Tips / Tricks to this repair?

I've read a few threads on the topic and they helped me diagnose the problem and I got the gasket from Cart Parts Plus.

Great site!
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Old 05-26-2016, 07:02 AM   #2
BigBlockMan
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Default Re: Crankcase Side Cover Gasket Replacement Questions...

It at least needs to be un-bolted so it can be raised slightly to get the side cover off. It does not have to be removed.
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Old 05-26-2016, 07:22 AM   #3
mayhem
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Default Re: Crankcase Side Cover Gasket Replacement Questions...

Quote:
Originally Posted by BigBlockMan View Post
It at least needs to be un-bolted so it can be raised slightly to get the side cover off. It does not have to be removed.
Is this what you recommend? Leaving it in and hooked up, but unbolting it from the belly pan/mount?
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Old 05-26-2016, 09:55 AM   #4
High roller22
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Default Re: Crankcase Side Cover Gasket Replacement Questions...

Yes u can do it that way but it's a pain takes less time to just pull it cuz then u might be able to find more problems
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Old 05-26-2016, 08:01 PM   #5
meimk
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Default Re: Crankcase Side Cover Gasket Replacement Questions...

I do this repair many times each season (cart shop at a campground). High roller I right - it's much easier to take the motor out first. I use the gasket and let the gasket sealer set up - with the bolts finger tight, before I tighten everything down. Replace that clutch side seal while you are in there.
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Old 05-26-2016, 08:48 PM   #6
lockman1
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Default Re: Crankcase Side Cover Gasket Replacement Questions...

To me? It's kind of "A horse, A peice"....
By not removing the engine, you wouldn't have to remove/disconnect pretty much everything to change the gasket,
however, bending over, working through the seat access isn't all that desirable!
Plus... aligning the cam while installing the cover would also prove to be difficult!

BUT... removing the S/G, exhaust, fuel and throttle lines, wiring,
then lifting the engine out of the seat access, and then reassembling,
might be a bit discouraging to someone that hasn't done it before.

It's your call!

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Old 05-27-2016, 10:50 AM   #7
mayhem
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Default Re: Crankcase Side Cover Gasket Replacement Questions...

I got it all torn down, case it open. Everything is clean and ready to go back together. Do you guys assemble them dry or use any kind of silicone? I'm using a OE Kawasaki gasket which is that red-ish paper with a waxy finish on both sides. I'm thinking dry, but open to suggestions.
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Old 05-27-2016, 09:46 PM   #8
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Default Re: Crankcase Side Cover Gasket Replacement Questions...

Disconnect the battery, cable from the throttle cam, intake hose, fuel line, starter/gen wires and unhook the sensor on the side. Disconnect the brake cables at the back, then unbolt the spring ends and shocks, and roll the whole engine and axle out from under the cart in one chunk.
Gaskets don't need sealer. Sealer should only be used on parts that don't have a gasket.
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Old 05-28-2016, 07:37 AM   #9
lockman1
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Default Re: Crankcase Side Cover Gasket Replacement Questions...

The manual does not call for sealer as Fairtax said!

Here is the torque sequence for the cover...
(click pic to enlarge)

casebolttorque.jpg
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