kzrider.com/forum/viewthread.php?tid=9285
Actually you need to remove the secondary shaft and starter clutch anyway before you can split the cases - the secondary shaft sits in the lower case only and is tied to the crank through the primary chain, can´t pull the cases apart without removing the shaft/starter clutch.
Rspector, seems like you already have the clutch basket off, right? If not, you´ll need to remove that to get to the secondary shaft bearing retainer bracket On the right side of the engine (sitting on bike) there´s a gear sitting on the end of the secondary shaft - remove the circlip, remove the gear and remove the bearing bracket that sits behind the gear if you didn´t already. You´ll need an impact screwdriver (hammer type) to get the bracket bolts off, they´re staked.
On the opposite end of the shaft there´s a bearing cap, right behind the altenator - remove the two bolts and pry the cap of. Use a soft drift (wood or alu) and tap the shaft out from the alternator side, it should come right out. Hold on to the starter clutch assy and pull the shaft out, then release the starter clutch from the primary chain, there you go.
(The engine in the pic has the topend and jugs removed, which is why the camchain is hanging down).
Btw, I have a load of pics from when I did mine, I´ll do a write-up as soon as I can and post a pdf.
Post edited by: onkelb, at: 2006/02/08 14:47