• Right crankcase
• Left crankcase
a. Remove the crankcase bolts,
hose guide and clutch cable hold-
Loosen each bolt 1/4 of a turn at a
time and after all the bolts are loos-
ened, remove them.
b. Remove the right crankcase "1".
• Place the crankcase with its left
side downward and split it by insert-
ing a screwdriver tip into the split-
ting slit "a" in the crankcase.
• Lift the right crankcase horizontally
while lightly patting the case split-
ting slit and engine mounting boss
using a soft hammer, and leave the
crankshaft and transmission with
the left crankcase.
Use soft hammer to tap on the
case half. Tap only on reinforced
portions of case. Do not tap on
gasket mating surface. Work slow-
ly and carefully. Make sure the
case halves separate evenly. If the
cases do not separate, check for a
remaining case bolt or fitting. Do
CRANKCASE AND CRANKSHAFT
c. Remove the dowel pins and O-
REMOVING THE BALANCER
• Balancer shaft "1"
Remove the balancer shaft with its
flat side "a" facing the crankshaft.
REMOVING THE CRANKSHAFT
• Crankshaft "1"
Use the crankcase separating
Install the crankcase separating tool
Do not use a hammer to drive out
REMOVING THE CRANKCASE
• Bearing "1"
• Remove the bearing from the
crankcase by pressing its inner
• Do not use the removed bearing.
CHECKING THE TIMING CHAIN
AND TIMING CHAIN GUIDE
• Timing chain
Cracks/stiff → Replace the timing
chain and camshaft sprocket as a
• Timing chain guide
Wear/damage → Replace.
CHECKING THE CRANKCASE
• Contacting surface "a"
Scratches → Replace.
• Engine mounting boss "b", crank-
Cracks/damage → Replace.
Rotate inner race with a finger.
Rough spot/seizure → Replace.
• Oil seal
Damage → Replace.
CHECKING THE CRANKSHAFT
• Runout limit "a"
• Small end free play limit "b"
• Connecting rod big end side