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splitting the cases for inspection purposes only


tools needed

17mm spanner
m8 allen key attachment
m6 allen key attachment
plastic or rubber mallet
small thin flat head screw driver

first off remove the engine front mounts from its lower mounting position on the cases



then loosen off and remove the 9 clutch case bolts





and gently lift off the clutch case





take note of the 2 spacer / washers on the gear selection rod / shaft dont lose them





now gently lift off the clutch basket





remove the gear selector mechanism






now remove the oil pump drive gear




then remove the circlip on the balance shaft primary drive gear





and lift the gear off off the shaft end





now remove the circlip off the crank shaft primary drive gears and remove the gears





loosen and remove the gear drum stop mechanism






and remove all the crank case bolts




once all the bolts are removed place the engine sat up as it would in the bike
now tap the shafts with a non metal hammer (rubber or plastic) only tap do not damage the shaft ends






the cases will begin to pry apart





at this point place the engine back on it side clutch case side upwards and gently lift off the 1 half of the crank case
note the spacer / thrust washer on the output shaft dont lose it




cases are split you can now inspect the innerds for wear or damage
 

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steve you should make some kind of book and just sell it on here lol, you would make loads
 

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I managed to get my engine out without the need of using a special tool on the swingarm , just undid did the bolt on the left and jobs a good un
 

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Discussion Starter · #33 ·
I managed to get my engine out without the need of using a special tool on the swingarm , just undid did the bolt on the left and jobs a good un
getting it back in might be a problem then as the swingarm pivot bolt adjusts the position of the swingarm and is handy to loosen it off so all the other mounts have more space to line up on reasemble
tighting the pivot pushes the swingarm loosening it pulls it
if its not done properly youll end up with the rear wheel out of allighnment with the front (which is a mot fail)
 

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Thanks for the great guide pego came to very good use!!

Cheers Jak
 

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pego any chance i could have a link to your photobucket please? can't see any pics and would like them if i'm doing this bottom end tomorrow lol
 

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that e- clip assortment box in the piston photo must come in handy the amount of e-clips iv lost from my carb needle grrrrrrrrrrr


Jak
 
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