Who has split the cases on the DS to get the crank out? Anything special to watch for?

 

It's a pretty straight forward procedure, you'll need the magnito puller
and the clutch basket holder to be able to remove and properly retorque all bolts. Also the middle plastic gear behind the clutch between the upper and lower oil pumps has to be removed to split the case. I could not find any instruction for this step in the shop manual and stumped me a few minutes. Also lay the motor on it's right(magnito side) as you are separating the two halves, this will keep the gears in places and keep the job more simple.
The following link gives some good ideas and pictures on tearing the rotax 650 downtear down
if you have any questions, just ask.

 

Will do. What about the flywheel puller? Do I need that?

 

magnito/flywheel puller are one and the same. Check with you BMW dealer on the puller it's supposed to be cheaper than the Bomb dealers.

 

I think the puller will be my hold up