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Posted on Jan 02, 2017
SOURCE: I am having trouble trying
I don't know what has not been removed so pardon me if I suggest something already removed. Remove the cylinder, intake manifold, magneto, stator, sprocket and shift lever. A case splitter is highly recommended. They don't cost that much and it makes for a clean separation. The two positioning guides will tend to hamper separation as will the crankshaft and output shaft as they slide through the bearings. That's another reason for a case splitter. Now would be a good time for new crank and output shaft bearings and seals and a new shift shaft seal. I assume the reason for the teardown is either a bent shift fork or broken gear teeth. If replacing a gear with a broken tooth or two, also replace any gears the broken gear meshes with. If you don't, you will get to do the gear repair a second time very soon after the first ride. Whatever pressure broke the teeth on one gear was also present on the meshing gear. It may look good, but it isn't. Please take a moment to rate my answer. Thanks.
Posted on Apr 13, 2011
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