Splitting the Cases

[BigRed350x]

good pic

 

the only thing i would have done was wash the motor off and the case so you dont get dirt and shit into it.

Edited February 18, 2006 by BigRed350x

[wesw]

sorry there didnt need to get all pissy about it and yell

[suzuki0702]

props to ya red...hey i always leave my clutch adjuster bolt in the hub because when i go to throw it all back together my clutch is still in same specs...not dawgin on ur work or nuthin just throwin it out there!

[[email protected]]

Compliments to RED on his information.  It's great he's trying to help everyone out. Can someone delete or at least move chases comments though?  BIGRED put so much effoert into making a "how to" thread for everyone and you have chase poping up every other post.  Just a thought, good goin BIGRED, nice to see someone thinking of others

475408[/snapback]

 

i deleted all my posts just so you can be happy ! seems like theres always some hissy fit goin on , on here

[BigRed350x]

sorry there didnt need to get all pissy about it and yell

475559[/snapback]

 

Sorry, I was at work when i made that post. Work stress gets to me during the day and I am generally not a happy camper.

 

Sorry.

[bansheeryder_69]

thats bad ass, if i burn my wheeler down this season I'll def. be using this thread to do my own shiz. Nice job bigred

[BigRed350x]

Pictures for part two will be up later tonight. I don't care if you post replies & stuff, but wait till all the pictures are up. The last pictures in the set will be of the tranny. When you see those, post away. That way people don't get all upset and mad like what happened to chase.

[Big Blue]

...and there is nothing wrong with the basket, you are only seeing oil markings on it, it's not grooved.

475555[/snapback]

 

OK the angle of the pics made it look that way, just less money you have to spend.

[BigRed350x]

OK next you will want to hammer down the little nut locker that is in there.

 

Here's a little trick if you do this out of the frame. Feed your chain into your sprocket and bind it up like it were going to bust your case (or case saver in my case). This will lock up the tranny and the clutch so you can losen that nut.

 

 

Here's the nut.

 

Get the washer behind it too.

 

Now remove the inner hub.

 

Remove the thick washer behind that.

 

Now remove the outer hub/basket or whatever you wanna call it.

[BigRed350x]

Here's a shot of the clutch basket. Notice that bronze colored bearing in there. That will come out if you want it to, but I'm not messing with it.

 

Here's a shot without the basket.

 

Remove the bearing that the clutch basket rides on. There is also a smaller washer behind that, but I didn't take that one out.

 

Next pull off the two gears on the crank. This little nut has a really high torque on it on some bikes. Mine was one of them. I had to smack on my wrench to get it off.

 

Here's the nut.

 

Take the washer off too.

 

Here's your water pump gear. These both slide right off.

 

Here you can see the large square key that holds your main drive gear.

[BigRed350x]

Pull that gear out.

 

This main drive gear has a shaft attached to the back of it.

 

remove the square key.

 

Next is the idler gear. Here's a side shot

 

remove the C Clip that holds the idler gear in place. You should NEVER reuse these, just buy a new one.

 

remove the washer next.

 

Then the idler gear.

[BigRed350x]

Next up is the kickstarter. This whole thing comes out as an assembly, and you can take it apart once out, but I'm not going to do that.

 

Grab that big spring and lift it off that little peg.

 

Rotate the entire assembly clockwise to release the keyed notch behind the springs & stuff.

 

Pull the kickstarter assembly out.

 

Here's another side shot.

 

There is a little C shaped clip that holds the two case halves together and holds the tranny bearing in place. We need to remove that. Not the baffle, but the little C shaped clip below it.

 

 

Losen the two philips head screws and take it out.

 

Oh yeah, here's that smaller washer that sits behind the Idler gear. Forgot that one.

[BigRed350x]

OK, next is the stator cover & all that crap.

 

 

remove the nut that holds the flywheel in place.

 

Put a dab of grease on that little indentation there before you try and use your flywheel puller.

 

Thread in the primary part of the puller (reverse thread)

 

Once that is tight, put in the secondary and use an impact gun on it until your flywheel pops off.

 

 

I stick that nut inside the flywheel since it's magnetic and you won't lose it.

 

remove the 3 bolts that hold the stator.

 

Here you can see how I modded my stock stator plate to advance my timing.

[BigRed350x]

remove the stator plate and the stator.

 

Push this little rubber seal through the case.

 

slide the plugs back out through the case and get the stator out of your way.

 

Here's another side shot.

 

remove the timing key from the crank

 

Flip that big ol hog over. If you didn't pull that little ball bearing out from the inside of the clutch , watch out for it when you tip it over. I lost mine. lol Stupid me.

 

Losen all those nuts on the bottom in a criss cross pattern a little bit at a time.

 

Flip it back over.

Losen the bolts you can see below. Compare the next two pics and you can see which ones to remove.

 

[BigRed350x]

Smack the cases with a rubbler mallet a couple times to break that seal between them. Smack them all the way around front and back and get them lose.

 

Lift the top case off.

 

 

Here's the inside.

 

Here's the tranny.