Going through the motor due to a cracked case. I plan on replacing piston,rings, crank bearing's, seals and gaskets ect.

1. Any tricks to getting the clutch drum off without the proper tool?

2. Should the rollers inside the movable drive face be clean or is it normal to have a small amount of oil and dust?

3. Any suggestions on the rebuild process and any simple performance tricks while I have the motor apart.

Thank's in advance

 

Welcome to the forums.
1) You need a impact wrench.
2) Of course it's normal to have grease and dust. Suzuki puts the grease in there. You need to check the rollers for flat spots.
3) Have the head shaved .030
Have you ever split the cases before? Getting the bearings on and the in crank straight isn't for the inexpierienced..

 

Will check the rollers for flat spot's.

With the head shaved .030 will I need to change jetting?

I have split cases a couple of times but always with a more experienced helper.

Looking at the bearing on the crank I can already see it will be a pain in the a$$.
The bearing spins freely so I may just leave it on.

I plan on having a more experienced helper working with me.

Thanks for the help and feel free to offer any suggestions on the rebuild.

 

Jetting will be fine.
FYI:: I use alot of heat.

 

Thank's for the tip all of the rollers had flat spots.