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Air-cooled two-stroke engine 2A.11
14.3 Undo the crankcase bolts evenly in a
criss-cross sequence
14 Crankcase halves,
crankshaft and connecting
$
rod, and bearings
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Note: To separate the crankcase halves, the
engine must be removed from the frame.
Separation
1
To access the crankshaft and its bearings,
the crankcase must be split into two parts.
2 To enable the crankcase halves to be
separated, the engine must be removed from
the frame (see Section 5) and the following
components must be removed:
Cooling fan (see Section 11)
Alternator (see Chapter 9)
Variator (see Chapter 2C)
Cylinder head (see Section 7)
Cylinder (see Section 8)
Piston (see Section 9)
Oil pump (see Section 13)
Reed valve (see Chapter 4)
Starter motor (see Chapter 9)
3 Tape some rag around the connecting rod
to prevent it knocking against the cases, then
loosen the crankcase bolts evenly, a little at a
time and in a criss-cross sequence until they
are all finger-tight, then remove them (see
illustration).
4 Carefully remove the right-hand crankcase
half from the left-hand half by drawing it off
the right-hand end of the crankshaft. Peugeot
produce a service tool (Pt. No. 750807) to do
this. Before fitting the tool, place the end cap
14.8a Measuring crankshaft oil seal inset
14.4 Drawing the right-hand crankcase
half off the crankshaft
(Pt. No. 68007) onto the end of the crankshaft
to prevent it being damaged. Alternatively,
use the set-up shown; thread the old
alternator nut onto the end of the crankshaft
to protect the threads and apply equal
pressure to both sides of the puller at all times
(see illustration).
5 Now press the crank assembly out of the
left-hand crankcase half. Peugeot produce a
sewice tool (Pt. No. 64706) and pressure plate
(Pt. No. 752168) to do this. Before fitting the
tool, place the end cap (Pt. No. 69098) onto
the end of the crankshaft to prevent it being
damaged. Alternatively, use the set-up
shown; thread the old variator nut onto the
end of the crankshaft to protect the threads
(see illustration).
Note: If the crankcase halves do not separate
easily, first ensure all fasteners have been
removed. Apply steady pressure with the tools
described and heat the bearing housings with
a hot air gun. Do not try and separate the
halves by levering against the mating surfaces
as they are easily scored and will not seal
correctly afterwards. Do not strike the ends of
the crankshaft with a hammer as damage to
the end threads or the shaft itself will result.
6 Remove the oil pump drive shaft and the
shaft bush from the right-hand crankcase half.
If necessary, heat the crankcase around the
bush while applying pressure to the shaft.
7 Remove the crankcase gasket and discard
it as a new one must be fitted on reassembly.
Remove the dowels from either crankcase half
for safekeeping if they are loose.
8 Note the position of the crankshaft oil seals
14.8b Tap the seals with a punch to
displace them
14.5 Pressing the crankshaft out of the
left-hand crankcase half
and measure any inset before removing them
(see illustration). Note which way round the
seals are fitted. Remove the seals by tapping
them gently on one side and then pulling them
out with pliers (see illustration). Discard the
seals as new ones must be fitted on
reassembly.
9 The main bearings will either remain in place
in the crankcase halves during disassembly or
come out with the crank assembly. To remove
them from the crankcase halves, heat the
bearing housings with a hot air gun and tap
them out using a bearing driver or suitable
socket (see illustration). Note which way
round the bearings are fitted. If the bearings
are stuck on the crankshaft, check their
condition (see Step 19) and only remove them
if they are unserviceable. The bearings must
be removed from the crankshaft with an
external bearing puller to avoid damaging the
crank assembly.
10 If required, remove the transmission
assembly from the left-hand crankcase half
(see Chapter 2C).
Inspection
11 Remove all traces of old gasket from the
crankcase mating surfaces, taking care not to
nick or gouge the soft aluminium if a scraper
is used. Wash all the components in a suitable
solvent and dry them with compressed air.
Caution: B e very careful n o t t o nick o r
gouge the crankcase mating surfaces or oil
leaks will result. Check both crankcase
halves very carefully for cracks and other
damage.
14.9 Driving a main bearing out of the
crankcase
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