Splitting the Motor Case

Before the cases can come apart, the gear selector box must be removed. First remove the two nuts which secure it to the case.

Then, simply turn the gear shift handle on the handlebars while pulling on the box. The gear selector box will pop free. Pull it away from the motor, but keep the gear shift cables attached.

Next, it is time to remove the nuts which hold the case halves together. Look over the motor and make a mental note of where all the nuts are located. Note that the bottom stud is mounted opposite of all the others and thus the nut is located on the wheel side of the motor. Begin with the four nuts around the crankshaft. Remove them in a star pattern. Then, move to the other nuts. Remove them in a star pattern as well.

Once all of the nuts and washers are removed, take off all of the removeable studs. The four studs around the crankshaft do not come off. A few of the other studs can be hard to get off, don't worry about it. Just take off all of the studs which come off easily when you push on them.

The cases should now come apart with a little persuasion. Use the kickstart lever as a handle, and using "rocking" pressure, pull the cases apart. If the cases are very stuck together, you can use LIGHT taps with a rubber mallet to push it apart. Additionally, there is a small metal tab on bottom of the flywheel side of the motor (near the oil drain) which can be used to help you. Use a drift and a hammer to LIGHTLY tap on the tab to help free the bottom of the cases from each other.

NEVER use a screwdriver or pry bar to pull the cases apart. This will damage the sealing surface of the cases and cause a leak, or in the worst case, could crack the case.

This is what you'll see once you get the motor apart.

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