I'm trying to remove the sump from my 03 R1 engine so I can fit a baffle.

I have removed all the bolts, but the sump is very reluctant to part company with the block. I've tried levering it off using a crowbar, but I'm worried that all I'll accomplish is bending the sump.
Is this normal?
Any suggestions for breaking the seal?

Thanks,
Martin.

Can u run a razor blade between to sump and case?

Is there a bit of a flange on the sump pan that sticks out past the edge pf the block? Tap on that with a mallet.

Is there a bolt in the centre of the sump that you've missed?

tap on the side of the sump pan with a soft faced mallet to see if it will slide or turn.

My '98 R1 sump was stuck on with the gasket. The paper gasket seemed to weld itself to the metal. It came off reasonably easily though.

I know this sounds like a silly question but have you removed ALL the bolts.

IIRC there is a bolt that is well recessed into the sump.

Try giving it a good few taps on the side of the sump with a nylon hammer to break the seal. Should just drop off then.

Beaten to it

Sure seems like you missed a bolt. The sump should pop off easy.

Be careful when you put the bolts back in place. The manual calls for a non setting thread lock.

Spoke to Malc Curnin (Sillybugger on the forum) about this. If you use too strong a compound and try to take it apart at a later date then you'll strip the threads.

Thanks Gents,

I'll have a look for that last bolt tomorrow.
Getting the sump far enough from the engine to get a knife in was one of the problems .

At least I know it's not normal .

Martin.

Just one thing, give it a tap with a rubber mallet to loosen the seal, but dont try to force it sideways to come off as it has a couple of metal dowels in there to locate it even when all the bolts are out.

Ah, THAT bolt in the centre of the sump.

I really can't work out how I missed it.

All I need now's the right gasket .

Thanks for not taking the piss,
Martin.