Endeavor engine

[Michael Scott]

I have now stripped the heads, barrels and top plates of the the Endeavor engine and want to dismantle the crankcase.

The through bolts/screws seem obvious or are there any surprises?

Any advice re the clutch spring - disassembly and future reassassemby?

Where can I get some helpful diagrams?
Regards
Michael

[Doug]

Michael,

The crankcase bolts are straightforward. What you see is how it is, no hidden surprises.

You will want to extract the timing pinion from the crankshaft before separating the cases. This can be a bit of a pain, due to the limited clearance behind the pinion for an extractor. The fingers of standard gear extractors typically are too thick to fit. I usually end up making a tubular extractor with a narrow lip to suit each type of engine I encounter. A picture of such a gear puller can be found in this post:

https://www.douglasmotorcycles.net/index.php?topic=240.msg609#msg609

If the crank wants to stay with the flywheel half, it will try to pull the pinion through the crankcase wall. Hence removing it first.

-Doug

[Michael Scott]

Doug
Many thanks re the gear puller - that will not be a problem.

How about the clutch spring? It looks a bit worrying!
Regards
Michael