Splitting the case

[my67xr]

What about the flywheel tool?

you wont need one,
if you leave that side together like when i did my Lifans, and minirider39 Alo did his Zongshens

 

[zwebx]

if i were you and had some space cash i would be checking the wear on the shift forks/tranny and replacing bearings and seals.. however if you dont its not nessorsary just means you may have to split the case again later

 

[Chickenwingz]

Finally got some spare time to work on the engine, so firstly i gotta get the head off then start working from the clutch side and take photos as i go right?

 

[zwebx]

Finally got some spare time to work on the engine, so firstly i gotta get the head off then start working from the clutch side and take photos as i go right?

That would be cool to see for people who have been lucky enough to not have to see the inside of one
+ if ya get stuck putting it back together it saves your ass

 

[Chickenwingz]

Can someone just briefly clarify the order i have to take the engine part in? Also i got brand new bottom end gaskets and 1 ride old head gaskets, do i have to replace the head gaskets?

 

[zwebx]

I have reused my head gasket like 5 times still no carbon even near the headgasket sealing surface so yeah you can re-use the head gaskets
and the valve cover gasket uses a o-ring seal so your lucky someone thought of that in china

 

[s2rt85]

just go back afew pages an read it dude

 

[my67xr]

see post #2.

you wont need to take the flywheel/stator off,
leave that side of the engine together.

 

[Chickenwingz]

Progress update 1:
Got the head/barrel off,opened the clutch cover, and don't know what to do from here, stuck on this bit what do i do from here?

 

[zwebx]

Un do the oil slinger nut with a hammer and screwdriver/clutch nut tool, put the piston on and put somthing under it if your having trouble holding it
then pull that off then undo the clutch spring retainer plate nice and evenly and then undo the other clutch nut in a similar fasion... pull that off and then worrry about the shifter parts etc etc..

to get the clutch nut tool on the spinner you may need to take the other two scews out

 

[Chickenwingz]

I don't have a clutch tool :/, should i order it or just use a screwdriver/hammer? Also is there another one of these clutch nuts under the spring retainer plate?

 

[my67xr]

yeah there is another nut the same holding the clutch on.
that's why i suggested buying one in post #10

 

[Chickenwingz]

Is this the one? http://www.ebay.com.au/itm/Clutch-H..._Parts_Accessories&hash=item1c32f3e94b&_uhb=1

 

[Chickenwingz]

bumppppppp

 

[zwebx]

Is this the one? http://www.ebay.com.au/itm/Clutch-H..._Parts_Accessories&hash=item1c32f3e94b&_uhb=1

yep, but i would buy this one if i were you http://www.dhz.com.au/buy/clutch-basket-oil-sling-remover-honda-crf50-thumpster-engines/TOOL-04
if not just use a hammer and a screwdriver for now to keep the work being done

 

[Chickenwingz]

How much work left from here?

 

[my67xr]

5 mins if you have the clutch nut tool, maybe 1/2 hour if you dont
depends on how easy the 2 locking/castle nuts come off.

 

[Chickenwingz]

I ordered it last night as using a hammer/screwdriver didn't work and caused too much wear on the nut. What do i have to do after i get the clutch basket off?

 

[my67xr]

did you read that link i posted up the top of the page, it explains all the steps.

the gear lever and arm that holds the shift star will need to come out after the clutch basket is off.
and possibly the shift star itself iirc, (been a while)
then you should be able to carefully split the cases
check out the gears and dogs on them for damage, the bearings, and check for worn shift drum forks too while you are at it.

 

[s2rt85]

not much to go mate you will be calling your self a bush mechanic at the end of this thread.lol