Fig. 2-77
Disassembling Engine (440 LC/550 cc Models)
1. Using the spanner wrench to secure the flywheel, remove the flywheel nut, lock washer, and flat washer; then remove the three starter pulley cap screws and remove the pulley. Fig. 2-79 B160
23. Remove the cap screws securing the crankcase halves. Note the position of the different-sized cap screws.
2
Fig. 2-78
AN015
2. Install the Crankshaft Protector Cap (p/n 0644-234) onto the end of the crankshaft. NOTE: A suitable substitute protective cap can be made by welding a 3 mm (1/8 in.) plate on one side of a spare flywheel nut.
24. Separate the crankcase halves by installing two crankcase cap screws in diagonal corners leaving the heads approximately 6 mm (1/4 in.) out. Using a plastic hammer, tap on each cap screw head until the halves separate. Remove the cap screws.
3. Using the Flywheel Puller/Spanner Wrench (p/n 0144-310) or suitable substitute, remove the flywheel from the crankshaft by tightening the puller bolt, striking the head of the puller bolt with a hammer, and tightening again. Repeat this procedure until the flywheel is free. Account for the key.
! CAUTION
! CAUTION
DO NOT drive any tool between the crankcase halves to separate the crankcase. Damage to the sealing surfaces will result.
To prevent damage to the crankshaft, the puller must bottom on the cap and not on the crankshaft. Also, do not thread puller bolts more than 12.7 mm (1/2 in.) into the flywheel. Damage to the coils may result.
A831
25. Remove the rubber bands holding the connecting rods; then separate the crankcase halves. Account for the two dowel pins. Lift the crankshaft free from the crankcase half and slide the two crankshaft seals off the crankshaft. Account for the C-ring and five bearing dowel pins.
2-19