Remove the engine (see Engine Removal in the Engine
Set the engine on a clean surface and hold the engine
steady while parts are being removed.
Crankshaft Sensor (see Crankshaft Sensor Removal in
the Electrical System chapter)
Clutch (see Clutch Removal in the Clutch chapter)
External Shift Mechanism (see External Shift Mecha-
Starter Motor (see Starter Motor Removal in the Electri-
cal System chapter)
Oil Pump (see Oil Pump Removal in the Engine Lubri-
cation System chapter)
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Oil Filter (see Oil Filter Replacement in the Periodic
Oil Pan (see Oil Pan Removal in the Engine Lubrication
If the crankshaft is to be removed, remove the pistons
(see Piston Removal in the Engine Top End chapter).
Remove the upper crankcase bolts.
First loosen the M6 bolts.
M6 Bolts [A]
M7 Bolts [B]
M8 Bolts [C]
Remove the lower crankcase bolts.
First loosen the M7 bolts.
M7 Bolts [A]
M9 Bolts [B]
Tap lightly around the crankcase mating surface with a
plastic mallet, and split the crankcase. Take care not to
damage the crankcase.
The upper and lower crankcase halves are ma-
chined at the factory in the assembled state, so the
crankcase halves must be replaced as a set.
With a high-flash point solvent, clean off the mating sur-
faces of the crankcase halves and wipe dry.
Using compressed air, blow out the oil passages in the