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Old 02-13-2011, 11:18 AM   #67
Brauhausbier OP
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Joined: Aug 2006
Location: SF Bay Area
Oddometer: 1,367
Yesterday with the invaluable help from my friend Luke (this is his ADV screen name too), we split the cases to replace the countershaft. In my short 11 year motorcycling career, this is my first case split What an experience!

Here we go:

Right Cover Off


Clutch Basket Next


Used an air gun to remove the 27mm nut behind the clutch basket. That worked well.


Removed the kickstarter, oil pump, ignition sensor, etc to strip out the right side components completely.

Next up was the case split. This took some time and a lot of elbow grease. Definitely the most difficult task in the whole process was this center case separation.

Here we go.
I made a case splitter using two 4' lengths of 2x2 an used a chunk of 2x4 to make fulcrum and applied the pressure on opposite sides of the case through the cylinder opening:


The start of some separation


Finally got the case pins separated


The propane torch is coming in handy trying to loosen up the case pins


Success


The crankshaft and transmission look good for a 17 year old XR


The new countershaft


Look how crisp the splines are


The old splines (just for reference)
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