When splitting the case, the cylider must be removed. The manual says if I don't have to seperate the head from the cylider, don't.
To remove the cylider, I have to take the valve cover off and remove the camshafts, right? That frees the timing chain. Then I can remove the cylider and head together?
Are there any tricks, tips, or pitfalls I should know?
muchas gracias

 

Im assuming the motor is out of the frame so you should be good to go.

 

You need to remove the 4 big nuts those hold the head and cylinder to the case. and the little allens on the bottom of the cylinder. The smaller bolts that hold the head to jug you don't need to remove and the head and jug will come off as an asssembly. Hope I didn't forget anything. Good luck. John.

 

You might get enough slack in the chain, to remove it from the lower gear, by removing the cam chain tentioner. I'm not sure why you would want to though unless you were working in a shop and flat-rating a trans repair.
If I were disassembling my own engine I would want to separate it for inspection purposes.

 

I am trying to get this done by next Friday night.(7 nights)
The engine is out and in my living room.
Never took one of these apart before. I guess I wil take the cover off and the cams/timing gear. After I lock the TDC bolt (I made one)
Oh, how do I find TDC?

 

If you have the cam cover off its easy. Pull a spark plug and bring the piston to the top then look at the cams. If the lobes are pointing up its close to TDC. If they are down and holding the valves open rotate the engine 360 degrees. Once close to TDC, look in the hole, where the TDC bolt goes, and line up the groove. Insert bolt

 

can I rotate the engine with an Allen wrench? Or do I need the special tool from BRP?

 

you can rotate it also by the counter sprocket. Another way to find TDC is to use a zip tie, remove the plug and insert zip tie. turn engine over until zip tie is at its highest point. Pull the plug for your locator pin and look in there with a flash light. you should see a groove in the counter balance on the crank. Insert pin to lock it down.

 

Thats really funny. Last time I set the timing on mine I used a zip tie in the side sparkplug hole to make sure I was reading the mark right.

Use a red zip tie........ much more accurate than a black or white one. LOL[img]i/expressions/face-icon-small-smile.gif[/img]

Ron