howard wallace Posted August 2, 2005 Report Share Posted August 2, 2005 Arun 1664, The proper tool is a copy of a clutch plate, it locks the inner ond outer basket together, while undoing the centre nut. A rattle gun will also undo it. Don`t go jamming screwdrivers and bars into the thing, or you`ll end up snapping bits off. Your also going to need a flywheel puller, a flywheel locking tool, and have a tension wrench for re-assembly. Have a good read ,and understand the manual before you go any further, as once you get into the gearbox, things are a bit more complicated. Quote Link to comment Share on other sites More sharing options...
howard wallace Posted August 2, 2005 Report Share Posted August 2, 2005 OOps, Just re- read your post, and to undo the primary gear drive you can also use the flywheel locking tool. It`s just a piece of bar with two 6mm pins, that fit into the matching holes on the flywheel. Quote Link to comment Share on other sites More sharing options...
arun1664 Posted August 3, 2005 Author Report Share Posted August 3, 2005 HW thanks for the advise, a quick copy of the (patent ignored) Charlie C flywheel holder sorted the drive pinion removal & I am happy (?) to report the arrival of two very slogged main bearings (rusty, suspect its that old pressure washer thing again) but all the other parts (bar a tired small end) seem fine. Quote Link to comment Share on other sites More sharing options...
wayne thais Posted August 4, 2005 Report Share Posted August 4, 2005 Mike, How does the piston look? Have you checked the piston to cylinder clearance? It should be about 1 1/2 thousands. Wayne Quote Link to comment Share on other sites More sharing options...
arun1664 Posted August 4, 2005 Author Report Share Posted August 4, 2005 Hi Wayne, the boreto piston gap takes a 0.04mm feeler gauge (shim) fairly snugly so its probably up around 0.002". To be honest the piston is starting to show its age but I have decided to use it (with new rings) and see how things go. I can take the barrel off during the winter and worry about it then if there is a real problem Have to say I was pleasently surprised at the price of sherco parts, hope to receive the parts tommorow & start the rebuild over the weekend. Quote Link to comment Share on other sites More sharing options...
howard wallace Posted August 4, 2005 Report Share Posted August 4, 2005 Arun, Sounds like your well on top of it !!! Assume your going to be replacing the crank seals, aswell ? If not, I`d recommend you do. If you are, Good. Don`t want to sound smart assed as I`ve no grasp of your mechanical knowledge, so if I`m telling you how to suck eggs, just let me know. Quote Link to comment Share on other sites More sharing options...
arun1664 Posted August 5, 2005 Author Report Share Posted August 5, 2005 Hi Howard, I trained as a Mechanical Apprentice (many years ago !) but about the most complex thing I deal with now on a practical level is a propelling pencil, so all comments/advise gratefully accepted Thanks for the help .. Mike btw i did replace the seals ! Quote Link to comment Share on other sites More sharing options...
arun1664 Posted August 29, 2005 Author Report Share Posted August 29, 2005 Have to say just completed my first trial on the bike post rebuild, no problems (other than its way to powerful for a rider of my standard, but a real laugh) Thanks for all the advise. Like the man said, its not to hard if you have some spannering experiance, take your time & and have a half decent work area. Quote Link to comment Share on other sites More sharing options...
yamaha_rocks Posted June 10, 2006 Report Share Posted June 10, 2006 The proper tool is a copy of a clutch plate, it locks the inner ond outer basket together, while undoing the centre nut. A rattle gun will also undo it. Don`t go jamming screwdrivers and bars into the thing, or you`ll end up snapping bits off. Heed the advice given above....Attempted to remove the primary gear nut on my son's sherco 200, and found it to be bloody tight, thought i was careful how i restrained the gear...but..ending up busting an ear of the clutch basket got a hold of a rattle gun the next day and was all too easy. Quote Link to comment Share on other sites More sharing options...
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