So, I'm going to have to do some repair work on my '03 636's transmission and figured it would be a good learning opportunity to tackle it myself. Motor is on the bench with everything I could think of removing already off. One question before I buy or beg to borrow a flywheel puller is do I need to pull the flywheel to split the cases to work on the transmission?
Any other tips or reccomendations are welcome.
Thanks, Kev

 

Do you have a service manual? As long as there aren't any bolts holding the cases together behind the flywheel, you should be OK.

 

I have a cd manual for the 05-06 and I have checked the parts diagrams from a couple different sources including Kawi.com. From all the diagrams I have seen, there is nothing behind the flywheel and starter clutch that is connected to both cases. The flywheel and starter clutch should just be attatched to the crank shaft, correct? I even pulled the starter motor and the starter gear, so that should be the only contact to the top case.
Thanks for the reply.
Kev

 

Update:
Just for anybody's general knowledge, yes you can split the cases with the flywheel installed on the crankshaft no problem. At least on a '03. I'm sure it's the same for most any bike, but who knows. Probably could have left the starter motor in place, too. Well, less weight when moving it with it gone.
I did notice before I tried to split them that the cam chain guide does need to be disconnected from the lower half. Single bolt, no problem, left the guide in place.
Now I have to figure out how to fix a transmission!