Unfortunately, yes, you must remove the alternator/rotor to get the friggin cases to come apart. And it is a real PITA. We took the motor down to the Triumph dealer to borrow their tools, but I actually broke the tool for removing the alt. Oops. It seems you can then just use a really big bolt that fits the threads, get it so it snugs up to the crank, then put a big wrench.handle on it and whack the handle really really hard with a big hammer to get it to break free initially. once it breaks free, it needs some oomph, but it will spin off then. Getting it back on is even harder since youy need to hold the motor down and apply about 6 zillion tons of torque. We waited until we had the motor back in the frame to attempt this part. That is when Ed (biker) came up with the band strap tool idea. Worked like a charm! And be sure to use a feeler gauge to gap the little magnetic sensor so you don't have to drain your new oil and do it. (Oops again)
Jaymo's bike? On the way to georgia last year his bike literally grenaded a piston inside when he ran out of oil. This was just after his big bore and we deduced that it wasn't broken in enough before hitting the slab at 90mph all day long. The rings didn't seat properly and oil then blew by the rings, eventually it ran out of oil, BANG! Dead on the side of the interstate at 9pm at Wytheville, Virginia. But on the bright side, Whytheville is a very nice little city with very friendly and helpful folk.
Lesson learned: ALWAYS check your oil level when you gas up. Had we done that, Jaymos would have just needed a new ring job and a gallof oil.
