Long story short, a car swerved into me doing about 60mph on the highway. The car tire hit the lower right side cowl that covers the pulser cover. my front end started to wobble but i was able to gain control. There was no where to pull over so i started to ride to the exit that was pretty close. However, i felt oil spraying all over my foot/leg so I knew I had to stop asap. I tried to go as slow as possible around the curve without using the throttle but the rear end slid out and I dropped the bike on the right side.

The cars tire made a big hole in the cowl and shredded the pulser cover. When the bike was on its side, all the rest of the oil spilled out. I would estimate at least 3-3.5 quarts leaked out when the bike was laying on its side so I know I wasnt running the motor dry when i was trying to get off the highway. The bike did turn off when it fell over.

Im hoping the damage is just cosmetic so i ordered all the parts that need to be replaced. My question is....there was a good amount of metal missing from the cover that was shredded by the car tire. Could any of this shrapnel been sucked into the motor? Of course I plan to drain the rest of the little oil that is in there and use a new filter.

Any other precautions I should be doing first?

Lucky you... yes, drop the sump pan. Something is inside may have imploded, not exploded.

Hopefully enough oil was in the sump to keep the mains and rod bearings lubed while you limped it along. Keep your ears open for ugly noises coming from the bottom end after you get it back together. I know a guy who dropped his and 2 months later the crank took a shit despite losing no oil in the fall. Evidently his oil pump sucked air and cavitated and the bearings ran dry for a bit.

I had a similar spill on my ZX10R. A good friend of mine is a helicopter mechanic and a motorcycle nut. He commutes 90 miles round trip daily and has taken several bikes past 100,000 miles so I trust his advice. We removed the damaged cover of course, then flushed the engine with Kerosene. Basically drained the oil, then leaned the bike to one side and poured kerosene into the engine from the open cover, and via the oil fill. I then dropped the sump cover as HUB has suggested and flushed it again.
After replacing the damaged bits n pieces I rode that bike for another 16000 miles before moving onto a KTM. I still see the bike here in town from time to time. So I am very happy with the results of all the effort.

EDIT: The bike was not started while this maintenance was performed.

* Last updated by: GPfan on 8/28/2015 @ 9:51 AM *

Also take your time with removing the hardware, one or two of the bolts where sheared and one was bent ever so slightly so take you time.
I am sorry this happened to you, but I hope you are ok. You never said if you were hurt in the spill.

Shouldn't the person who hit you insurance be taking care of this? Have a dealership fix it.

Yea i guess ill pull the pan to see whats in there. I some cuts on my arm but im fine. The car that hit me never stopped. I was too concerned with getting to a safe place to stop.

Some other questions.

I had to replace the clutch cover because the when the bike slid, it scrapped the cover pretty bad and removed good amount of material from the cover by the oil gauge that there was a slight leak there.

I have a new clutch cover and new oil gauge (glass). The service manual says to "press the gauge so that its projection faces the inside using lubricant." .....does the gauge just snap into place without the use of any sealant? I have the correct Kawasaki liquid gasket for the cover.

Also, the manual says to use sealant where the mating surface of the crankcase touches the clutch cover gasket. In the picture they indicate only two small sections to use sealant. Is that just to secure the gasket in the correct place to make sure it sits proper when putting the cover on? Your not supposed to put sealant on the entire surface?

Thanks guys

Sealant goes only where the case halves meet.

Use sparingly, let it skin over after application before fitting the clutch cover.

* Last updated by: hagrid on 8/29/2015 @ 3:25 PM *