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Use 6mm allen wrench to turn forcing screw and begin to separate cases. See
photo III-23. Turn forcing screw a little at a time. If it seems to require a lot of
effort, check to make sure all the case bolts have been removed. Do not use
screwdriver to pry cases apart! The transmission gears will not be able to sep-
arate during this process, so the countershaft will have to pull through the left
case as the cases separate. Gently tap on the splined countershaft to ease it
through the seal and bearing and allow the left side case to be removed.
Crankshaft
- Use the crankcase splitting tool again to remove the crankshaft
from the left side case. Inspect the bearings for wear or damage. Rotate bear-
ings and check for rough or loose areas. Do not spin bearings dry or with
compressed air as damage will result. If bearings need to be removed from
crankshaft, use a bearing puller and a press. Rotate connecting rod and check
for play or binding of the big end rod bearing. Check flywheel and clutch
mounting surfaces for wear, damaged keyways or threads. If possible, use a
dial indicator to make sure both sides of crankshaft are true and do not wob-
ble. Have crank serviced or replaced as needed.
Note:
install crankshaft seals after crankshaft has been installed and both
cases put back together. If the seal is installed before crankshaft installation,
the seal may be damaged or pushed out when cases are put back together.
Transmission -
If the transmission gears or shafts need servicing, remove
the nut and then the large driven gear (just to the rear of the clutch assem-
bly). On newer models, the gear is splined and can easily by removed. On
older models, the driven gear fits snugly on the transmission mainshaft using
a keyway. A puller may be needed to remove the gear if the cases are not
split. If the cases are split and a puller is not available, put a metal dowel on
the end of the mainshaft and tap gently on the end of the dowel with a ham-
mer. Do not attempt to remove the transmission shafts without removing this
gear first, as the water pump drive gear will not allow the countershaft to
move outward far enough for removal if the mainshaft is not free to move.
Inspect the gears, shafts, and bearings closely for damage, bending, or
excessive wear. Also check the cases for damage or cracks around the bear-
ing bores and the swingarm pivot boss. Welding the cases is not recommend-
ed due to potential warpage. Replace any damaged parts.
Reassembly -
Make sure all gasket material has been removed
from the engine cases and any dirt or debris flushed away.
Always replace seals and gaskets with new parts. Lubricate
crankshaft bearings with clean premix oil. Install crankshaft
bearing as far as possible into right & left cases. Use a large
socket to press bearings into place by pushing on the outer
bearing shell only. Use a press if available, otherwise use a
hammer to tap bearings evenly into place.
Position crankshaft into right side case, making sure connect-
ing rod points up between cylinder studs. Squeeze crankshaft
into case by hand while tapping crankshaft counterweight gen-
tly with a brass or plastic hammer in a criss cross pattern to
seat crankshaft into right side case.
Install transmission shafts and gears into right case (if
removed previously). Check gear alignment to make sure the
gears engage fully and turn smoothly. Check that the counter-
shaft gear drives the water pump assembly properly. Lubricate the transmission shaft bearings bearingwith transmission oil, and the
connecting rod bearing with premix oil.
Check that the 2 case alignment dowel pins are in place. Coat case gasket with high tack adhesive, then align gasket and install
over dowel pins.
Place left side case over crankshaft and align transmission shafts with bearings in case. Squeeze cases together by hand, then use a
brass or plastic hammer to gently tap left case around flywheel and transmission area to ease cases together. If necessary, use two C
clamps on front and rear mounting bosses to help pull cases together while tapping with hammer. Do not use excessive force, stop
and start over if cases will not come together without damage. When cases are close enough together, check to make sure gasket is
Use case splitting tool to separate cases.
Do not pry between cases!
Install case splitting tool as shown.
Driven gear (opposite side) must be removed before transmission
shafts can be removed from case.
Note:
Countershaft
must pull
through case
mainshaft
countershaft
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