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Lower rebuild?

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So I thoroughly f-ed up my right side case by over tightening a cover bolt.... so I’m going to replace it... 

is it super difficult to do this? I’m concerned about getting the gears back in correctly and have yet to find good instructions for doing it. 

If I do end up doing this myself are there other things I should replace while I have it torn apart? Like the starter, or other hard to access parts?

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If it was a center case bolt stripped out I’d go that route. But a side case I’d try this before splitting the cases. It’s not expensive and if it works great. There are other products out there that are similar too helicoil 

60A7EC53-7F63-455A-BB25-C29B047603A0.jpeg

C71344E5-FDF7-483A-8289-C6DF4B5B9DF5.jpeg

Edited by 5Rs

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11 hours ago, 5Rs said:

If it was a center case bolt stripped out I’d go that route. But a side case I’d try this before splitting the cases. It’s not expensive and if it works great. There are other products out there that are similar too helicoil 

60A7EC53-7F63-455A-BB25-C29B047603A0.jpeg

C71344E5-FDF7-483A-8289-C6DF4B5B9DF5.jpeg

Unfortunately I didn't strip the hole, or break a bolt, I broke the actual case, which is only 3 mm thick around the screw hole. . . from now on I'll have my torque wench handy every time I tighten anything on my bike (like I should have to begin with). 

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Bummer.

This is one of the best tear down threads I've found:

https://www.southbayriders.com/forums/threads/106693/

along with the re-assembly:

https://www.southbayriders.com/forums/threads/107092/

 and of course there are plenty of vid's on youtube.

 It's for a 250x, but the 450x is quite similar.   Of course it goes without saying you'll want a shop manual.    You'll also need a flywheel puller and a case splitter is not a bad idea.  You can get the Tusk branded tools at a reasonable price.

 and you can always ask questions here.

Jim.

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4 hours ago, Jim Dettman said:

Bummer.

This is one of the best tear down threads I've found:

https://www.southbayriders.com/forums/threads/106693/

along with the re-assembly:

https://www.southbayriders.com/forums/threads/107092/

 and of course there are plenty of vid's on youtube.

 It's for a 250x, but the 450x is quite similar.   Of course it goes without saying you'll want a shop manual.    You'll also need a flywheel puller and a case splitter is not a bad idea.  You can get the Tusk branded tools at a reasonable price.

 and you can always ask questions here.

Jim.

Thanks Jim!

 

first thing I need to do is reorganize my garage (aka clean it). 

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