Question about 2004 Suzuki DR-Z 125

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Do you have to disassemble the transmission to split the crank case?

And will i need new bearings if i split it?

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Yes you need to split cases to check the transmission and once you've spitted the cases, it is best to renew the bearings cause is quite a trouble to do that again soon if any of the bearing are about to go bad.

Posted on Feb 08, 2012

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1 Answer

Big end bearing has disintegrated. What is the easiest way to strip the motor & remove crankshaft


If it's a 2-stroke, you'll need a crank puller and a case splitting tool to get this done, the crank is press fit into the magneto side bearing. If it's a 4-stroke, no special tools are required. Always pull the clutch side case off, leaving the transmission and crank in the magneto side. It's way easier to keep the transmission organized this way. Good luck!

Jun 09, 2011 | Yamaha Renegade 200 Motorcycles

1 Answer

How too replace connecting rod on a ttr 125l. I have a 2001 ttr 125 with a seized conn big bearing. and I would like to know the proper way of splitting the crank too replace it


The top end comes off then the left and right side covers, flywheel, clutch and shift shaft. Now a case splitter is used to split the center case halves. To replace the bearing you will need a hydraulic press to disassemble and reassemble the crank halves. If the bearing is seized you should replace the bearing, crank pin and the connecting rod. The crank must be realigned using twin dial gages. Personally, I suggest a new crank assembly be purchased from www.babbittsonline.com ( $241 ). I would replace the crank end bearings at the same time and also the sprocket shaft outer bearing and seal. Please rate my answer.

Jan 03, 2010 | 2002 Yamaha TT-R 125 L

2 Answers

I need to know how to dis/reassemble a 1974 DT 360?


A service manual ( if you can find one ) is what you need. The second thing you need is repair parts. They are pretty hard to find. Babbitt's, a well known distributor, only has parts left in stock for the top end. Go to their website, www.babbittsonline.com/parts/viewbybrand/parts.aspx
and you can see what is left. There's also a diagram of the crankcase center halves. If you can't get the repair parts, spending hours doing an engine teardown is fruitless.

The teardown will require a flywheel puller, a case splitter, an impact driver, and a torque wrench (somewhat optional). Disassemble the top end then remove the left and right side case covers. Remove the flywheel and related electrics, the clutch, crankshaft drive gear, oil pump, kick starter, shift shaft assembly, shift drum end cap and index pins. Now remove the screws on the center case and you can then split the case. This gives you access to replace shift forks, gears, and bearings. Note that crank seals can be replaced without splitting the case.

I am not trying to be a smart *** here, but re-assembly is just the reverse of dis-assembly. This is why a manual would help. Another potential source for parts is to Google motorcycle salvage yamaha .
The normal things you would need to replace inside the center case would be bent shift forks (if shifting is the problem), busted gears, crank bearings and seals, and sprocket shaft bearing and seal. All else can be replaced by removing just the side covers.

Dec 10, 2009 | 1974 Yamaha DT 360

1 Answer

I need to remove a main drive bearing in the case but can only get to one side of ut


The only way to remove a crankshaft bearing is to split the center case. Don't replace just one bearing, replace both while you are in there. Be sure to install new crank seals as well.

Oct 26, 2009 | 2004 Yamaha YZ 125

3 Answers

How much work is there and how much for a bottom end bearing.to be done ..any one no pls


The connecting rod bearing is inaccessible without disassembling the crankshaft halves. This is strictly a job for the shop having a two ton hydraulic press. I think you are actually referring to the crankshaft end bearings. Either way, the job doesn't get much bigger >
  • The engine comes out of the frame, the top end comes off.
  • The flywheel and stator come off as does the entire clutch and kick-starter. The shift shaft gets removed as well.
  • The center case gets split then all the gears and shift drum and shift forks come out.
  • Remove the crank and then the bearings and seals.
  • Install new bearings and seals and also a new sprocket shaft left bearing and seal. A new shift shaft seal would be good also.
  • Now take the remaining 100 parts and just put them back the way they were. Experience is desirable at this point.
Don't even think of doing the repair without a factory service manual. You will need a case splitter, impact driver, flywheel puller, gear puller and a torque wrench to do the job properly. Personally I encourage you to do it > but not without a clean work area and bench, the proper tools and a service manual. Check with the dealer as to what they would charge to replace the crank end bearings. Probably $900 to $1100. You can buy the tools and do the job yourself for about $250. Now I want to emphasize that you ARE mechanically inclined, RIGHT?

Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part and/or the notation "Not Available" is in the description, the part is not in stock. www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx

Click on the following tabs > CLUTCH, CRANKCASE, CRANKSHAFT / PISTON, CYLINDER HEAD / CYLINDER, TRANSMISSION, and also GEAR CHANGE MECHANISM and GEAR CHANGE DRUM/SHIFT FORKS. This will give you an idea of what you are getting into. The best case is you fixed it cheap and now have tools and experience as well. The worst case is you now have tools, a box of parts to take to the dealer and experience.

Best wishes, Tombones49
Can I get a “very helpful” rating on this answer?

Sep 05, 2009 | 2001 kawasaki KMX 125

1 Answer

Need to change the crank on a Gilera Runner Purejet. any ideas.


easier to fit a second hand engine, prob cheaper as well, try a breakers. need special tools to split cases and to pull together after new crank in, to get end float on crank, tricky. won't las a mile if bearings side loaded.

Jun 14, 2009 | 1984 Honda CB 700 SC Nighthawk

1 Answer

How do I take off the Magneto off a 2003 Yamaha 125


If replacing the piston pin bearing no splitting is needed. If replacing the crank pin bearing splitting is needed. You knew that I am sure but I had to clarify. The flywheel is held in place with one washer and a nut on the end of the crank. Timing is accomplished with a woodruff key on the shaft. Using a flywheel puller tool is the proper method. It is a simple and low cost tool and it sounds like you have enough knowledge of engines to need one now and in the future. In a worst case scenario, use a mallet, striking the flywheel on four points around the perimeter of the wheel and in an "outward" direction. With some luck the flywheel will pop loose.

When you are purchasing the flywheel puller, buy a case splitter also. Also reasonably low cost, it makes the splitting clean and easy. I strongly suggest you install new crank bearings and seals. Whatever caused the crank pin bearing to go bad did not do the crank main bearings any good either. I would hate to see you have to split the case again eight weeks from now.

How are you planning to separate the crank halves, re-assembly and truing of the crank? The dealer should do this part. I can't find a free repair manual on the web but the next best is a parts diagram. Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock.
www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx

Top rating on this solution? Thanks!


May 24, 2009 | 2003 Yamaha YZ 125

1 Answer

I am considering replacing the entire crank assembly. any tips?


You will need a flywheel puller you can purchase from denniskirk.com or other mc tool outlet. This is a must tool. Otherwise you can do the job with simple hand tools such as wrenches, allen wrenches all metric of course, and a rubber mallet. It will take about two hours to disassemble. your crank will have to be rebuilt by a shop with a crank jig and a press. the halves must be aligned perfectly. then wash everything very good make sure you have all the exploded bearing cleaned out then make sure again, and reassemble. best wishes!

May 11, 2009 | kawasaki KX 250 Motorcycles

1 Answer

How to disassemble crank bearing on Schwinn Mesa Mountain Bike


You wil need a couple of special tools, or be fairly creative with the tools you have.
  1. remove the dustcovers in the crank arms at the crank axle
  2. loosen the crank retaining nut/bolt.
  3. thread in a chank puller and pull the crank arms.
  4. remove the lock ring on the adjustable side of the crank axle (Requires lock ring wrench)
  5. remove adjustable bearing cup.
  6. remove axle and bearings
  7. replace or repair as needed.
Once you have it opened up ou can determine if you need new bearings or crank axle.
to assemble, reverse above procedure, insuring bearing play is minimalized.

Hope this helps.
Ed

Apr 16, 2009 | Schwinn Mesa Gs Mountain Bike

1 Answer

Suzuki 125rm manual


Find a manual by Googling " Motorcycle service manuals "
or go to www.repairmanuals.com

Installing new crank bearings is not a simple task. you will need a 3/8" impact driver, flywheel puller, case splitter and torque wrench. The top end comes off then the side cases, flywheel, flywheel electrics, clutch, shifter shaft, Crank drive gear and output shaft sprocket.

Split the case leaving the gears on the shafts and the shift drum and forks in place but out of the gearbox. Remove the crank and then remove the bearings from the crank or from the center casings depending on where they decide to stay when the case splits. Remove the crank seals from each center case half. Install new seals then install new bearings into the center casings.

Now just put everything back together.
By the way, now would be a good time to stick in a new output shaft (sprocket) bearing and seal. Be sure the OHC is timed correctly when installing the cam chain. Bad timing = bent valves.

Please rate this answer. Best wishes amcampailla

Mar 14, 2009 | 2003 Suzuki RM 125

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