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Crankcase Disassembly
NOTE: Engine
must
crankcase or crankshaft service.
NOTE: The CVT system, starter motor, starter drive,
flywheel, stator, oil pump and transmission can be
serviced with the engine in the frame.
NOTE: Use care during the crankshaft removal
process to avoid damage to the cam chain.
1.
Remove engine, cylinder, piston, and stator assembly.
2.
Loosen crankcase screws (circled) evenly and remove.
3.
Separate right crankcase from left by tapping gently with a
soft face hammer evenly around the case as required. Leave
the crankshaft in the left crankcase half. Do not attempt to
remove crankshaft with right case or cam chain will be
damaged.
Crankshaft Removal
1.
Support the crankcase in the upright position as shown.
2.
Lift cam chain and move it as required to disengage the
chain from the crankshaft sprocket teeth.
3.
Remove crankshaft.
be
removed
to
perform
ENGINE / TRANSMISSION
Crankshaft / Cam Chain / Sprocket
Inspection
1.
Inspect the crankshaft main bearings and cam chain
sprocket for wear or damage.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. Look for signs of discoloration,
scoring or galling. Turn outer race of each bearing.
Bearings should turn smoothly and quietly. The
inner race of each bearing should fit tightly on the
crankshaft. The outer race should be firm with
minimal side to side movement and no detectable up
and down movement.
2.
The connecting rod big end bearing is a roller bearing.
Visually inspect connecting rod big end for scoring,
damage or excessive wear. If connecting rod passes visual
inspection, measure radial clearance carefully with
crankshaft clamped in V-blocks at points "A" and a dial
indicator measuring total up and down movement "B".
Compare to specifications. If clearance is excessive replace
the crankshaft assembly.
A
3.
Clean crankshaft and all oil passages in crankcase and
crankshaft.
4.
Be sure oil collector passage on right side crankshaft
counterweight is clear. This passage collects oil supplied by
the right side crankcase oil passage (from the oil pump) and
moves it by centrifugal force to the connecting rod big end
bearing. See "Oil Flow Diagram" on page 3.10
5.
Remove cam chain. Inspect chain for worn or missing
rollers or damage. Replace if worn excessively or as part
of any crankshaft repair.
Note: Install new cam chain as
Note: Install new cam chain as
a part of crankshaft repair.
3
B
A
3.27
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