[Load62]

Alright, I want to admit my stupidity here. So don't be too mean to me haha. Long story short I cracked the crankcase and clutch cover trying to do an oil change. Was told to use a torque wrench but I used it wrong or it was calibrated incorrectly.

As a summary:
What parts do I get
What tools will I need
Any tips on the replace
Any guides to the swap out

Attached is a picture of the crack. It starts past the gasket where the oil drain bolt is where it attaches to what I assume is the crankcase. I have found the parts that I think I need for it. (https://partsfinder.onlinemicrofiche.co ... 0-%20RIGHT)
I would like to know what other parts aside from these that I will need.

While I am at it, I am going to replace my front and rear tires as well as my rear sprocket. Are there specific tools I will need for that? Or any guides that yall would trust? I apologize for the chaotic post, but I was going to do an oil change then go riding with some friends tomorrow and then cracked my stuff then found out it was minimum $250 to replace it all.

[JimDirt]

Hopefully this helps







As far as what to replace .... obviously the case , and gasket ... the rest is going to depend on the condition of each part/seal , etc. , as you remove them ....... If you need more Manual pics , just say what part you need about , and I will post it up ...

As far as tools , the main "specialty tool" would be the clutch holder so you can undo the main clutch hub nut , as well as for re-torquing it

You can use this https://www.crfsonly.com/catalog/produc ... ts_id/3829 or this https://www.crfsonly.com/catalog/produc ... ts_id/1303 , and may need this
https://www.crfsonly.com/catalog/produc ... ts_id/3228

I think that is all you need except the basic sockets/wrenches , and a torque wrench , preferably a 3/8" drive digital one that reads in inch lbs as well as Neuton Meters .....

If you get stuck on something just ask ...... I will be riding again tomorrow , so I won't be back till early evening (I am on Mountain time) , but as soon as I get back I will check the forums ....

[Load62]

Hey jim, thanks for the quick response. Sadly I was browsing the incorrect parts and so I was looking at the right side whereas its actually the left. The picture I included was a picture of the oil drain screw. So I am trying to figure out which part of the crankshaft actually needs replacing? Seeing as how there seems to be cover then two centers then another cover on the opposite side. So if you look at it as parts 1-2-3-4 with 1 being the left side with the engine oil and 4 being the kick start, Part 2 is cracked about half an inch.

[JimDirt]

OK , lets refresh here .... You are working on the Ignition cover side ?? , or the Clutch side ??? , confused ... , as the clutch side has a main right case half , a clutch/gear and water pump cover then the clutch (round) cover , the Ignition side has the main left case half , and the ignition cover (where the stator is)

So in link 1 or link 2 , or link 3 , what part are we talking ?? , and what link ??

(1)
https://partsfinder.onlinemicrofiche.co ... 0CRANKCASE

(2)
https://partsfinder.onlinemicrofiche.co ... 0-%20RIGHT

(3)
https://partsfinder.onlinemicrofiche.co ... 20-%20LEFT

[Load62]

Sorry jim, It is in fact the left side, when I was initially looking at the parts, I clicked the wrong part diagram. Apologies for the wrong information.

[JimDirt]

OK , if , it is just the Ignition cover , then no special tools needed , just undo all the bolts (after draining the oil) and pull it off , if it is the main left case , then , that opens up a whole new issue , the entire engine will need to be disassembled if that case is cracked/broken and you would need a Flywheel Puller made for your bike , as there is a brass collar on the end of the crank and if it gets damaged or crushed in any way , you would have to replace the crank , as it is a oiling seal and if it is compromised , the oiling to the rest of the engine will stop and lead to a major disaster ...... and the engine needs to be removed from the frame , as you will not be able to replace the main case without removing the engine (which requires removal of the swingarm) basically you will have a bare frame with forks , so almost complete disassembly of the bike .....you can have the engine on the bench ready to come apart in a hour or so ......

The rest is just normal disassembly , no special tools ( you won't have to pull the clutch basket but you will have to pull the right side outer cover (kick starter , water pump , so you can get at the balancer shaft because that has to be disassembled to remove the left case) , but the head , cylinder , needs to come off before the case can be removed (you won't need to remove the piston from the rod , just the head/cylinder) , if it was the clutch side main case half , the clutch basket would need to be removed with a holder tool as I showed before , and the same steps would apply as to the left case half with cylinder and head etc. .... , if it was just the outer clutch cover , then just the kick start would need to be removed along with the water pump .............. I would highly recommend getting a Factory Honda Service Manual before pulling the engine apart .... it will save you the heartache of having something else go bad like this by not knowing a specific setting ...... and you will be able to see where everything goes and what torque is supposed to be on each bolt/nut ....

On a side note , when draining oil , I never torque those bolts , as they have a crush washer , so as long as it is snug (like gently seat , then maybe 1/4 turn) that is usually sufficient to keep it from leaking or coming loose ....

But it looks like you have a job ahead of you ......You will learn a lot with this one ....

[Load62]

yeah its only the left main case that is cracked. However I believe the left case cover has a few stripped spots. So far my cart for parts is about $600 haha. Oh well.

[JimDirt]

I feel for ya ....