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Make sure that you have removed all the
fasteners. If the cases are hard to
separate later, check for any .fasteners
you tnay have missed.
11. Pry the crankcase halves apart, using the
largest tool that will fit in the 4 pry points
(Figure 120). There are pry points on both sides
of the engine. If you encounter resistance,
check for bolts you may have missed.
12. Lift the bottom crankcase half off. See
Chapter Six for transmission removal and
Keep each crankshaft bearing insert in
rts original place in the crankcases. If
j$ou are going to assemble the engine
~ Y t h the original inserts, they must be
installed exactly as removed in order to
prevent rapid wear.
13. Remove the starter clutch/secondary
sprocket from the crankcase (Figure 121).
Check the crankcase halves for cracks or
fractures in the stiffening webs, around the
bearing bosses and at threaded holes. While
such damage is rare, it should be checked for,
particularly following a major failure (such as
piston breakage, bearing failure, gear breakage)
or after a collision or hard spill in which the
engine suffers external damage.
If cracks or fractures are found, they should
be repaired immediately by a reputable shop
experienced in and equipped to perform
repairs on precision aluminum castings.
The upper and lower crankcase halves are
machined as a pair; if one half is not usable,
both must be replaced.
Bearing and Seal Replacement
The crankshaft oil seals should be replaced
whenever the engine is disassembled. Seals
should be installed with their marked side
facing out of the engine. The secondary shaft
bearing (A, Figure 122) and shift drum bearing
(B) should be replaced if there is any doubt
about their condition.
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