How to split the Z400 engine case - Page 2

Now I found I don't have a real good pic of the next part. OH well you should have a Manual and the pic in there is good. Next we need to get out the Impact screwdriver(I love that tool) and take off the screws that hold the GearShift Pawl Lifter off and the Stopper Arm off. The stopper arm has a spring that you can pull off easy with some pliers but is a pain to put back on there when you install. Now you should see this.



That little ball of joy you see there is the Gearshift Cam Driven Gear and is a spring loaded. I like to take that off and wrap it with a zip tie to keep it together while being stored. The shaft it rides on just comes off with a 10mm bolt.



Now we move to the counter balance. This is where I use the penny between the gears while I could use the off set wrench. Any way, put the 17mm on the impact and the penny in-between the gears as shown below and zip the nut right off.




Now you will notice the indexing dots that must be aligned when you get everything back together.



Next I get a new penny and place it back into the gears. 27mm Socket it need for the nut on the crank and it's LEFT HANDED THREADS. Which means you set the impact to the setting that normally tightens bolts down and it will loosen this ONE nut.

Now that the nuts are off, to remove the counterbalance gear I just use a couple magnets and it pulls right off. Just make sure you get the pin that holds the gear in place. Next you can remove the series of gears on the crank shaft until you get to the primary drive gear. This one is always a pain. I use a small pry bar and slowly pry on the gear while spinning the crank to different positions to work the gear off. It is going to take a while but it's the only way I know.

Ok now we are all done with that side. Spin the motor around and we can finish up on the flywheel side. Dig out the flywheel puller and put it to work. Notice I don't unbolt the 5m allens because it's not needed. You should look like this(minus the gear we removed earlier)...



Next you will see a key embedded into the crank shaft. This comes out with some light tapping with a screwdriver and mallet. After that the Starter Driven Gear will come right off. Now we are almost there.

The final case bolts are on both sides of the cases. There are 8 bolts on the Clutch Side and 6 Bolts on the Flywheel side. Once they are removed and you counted 3 times to make sure you have all 14 bolts it's time to strap the case splitter on. I use a 2x4 that I setup to do the job with a simple puller from Autozone. As you pulling the cases apart keep a close eye on them to see if they are coming out evenly. There is two dowel pins on both ends and the cases like to stick there. I use the rubber mallet to tap the cases(I said Tap) and they usually free up. Also tap the trans shaft the clutch rids on so that it stays in place. This will keep your trans parts all in the right places. My first set I didn't notice and had to put the trans all back together and it was a pain.




Well that's it this is what you should have now...