A Upper crankcase 6 rnm bolts (A), 8 mm bolts (B) and 10 mm (C) bolt

pattern, until they are finger-tight, then remove them (see illustration). Note:As each bolt is removed, store it in its relative position in a cardboard template of the crankcase halves. This will ensure all bolts are installed in their correct locations on reassembly.

8 Unscrew the twelve 8 mm lower crankcase (crankshaft and balancer shaft journals) bolts (see illustration 20.7).Unscrew the bolts evenly, a little at a time in a criss-cross pattern until they are finger-tight, then remove them, along with the washers and place them in the template. Discard the washers as new ones should be fitted on reassembly.

9 Carefully lift the lower crankcase half off the upper half, using a soft-faced hammer to tap around the joint to initially separate the halves if necessary. Note:If the halves do not

B Triangle (arrowed) denotes use of sealing washer on adjacent bolt

separate easily, make sure all fasteners have been removed. Do not try and separate the halves by levering against the crankcase mating surfaces as they are easily scored and will leak oil on reassembly. The lower crankcase half will come away with the gearchange mechanism external components (if not already removed) and the selector drum and forks, leaving the crankshaft and transmission shafts in the upper crankcase half. The lower main bearing shells and the lower balancer shaft bearing shells should also come away with the lower crankcase half. Remove them if they are loose, noting their locations (see Sections 25 and 26).

10If required, remove the three locating dowels from the crankcase if they are loose (they could be in either crankcase half), noting their locations (see illustration).Similarly remove the two oil nozzles, noting which way up they fit.

11 Refer to Sections 21 to 30 for the removal, inspection and installation of the components housed within the crankcases.

Reassembly

12Remove all traces of sealant from the crankcase mating surfaces.

13Ensure that all components and their bearings are in place in the upper and lower crankcase halves. If the transmission shafts have not been removed, check the condition of the output shaft oil seal on the left-hand end of the shaft and renew it if it is damaged or deteriorated (see Section 28); it is sound practice to renew this seal anyway. Apply

Date: 2016-01-14; view: 523