Durring teardown the first thing I noticed was I could grab the clutch basket and shake the whole thing up and down. Also could do the same to the flywheel.
I continued to strip the cases and inspect everything to decide what I need to order. I ended up ordering every bearing, seal and gasket OEM.
Sent the cylinder, crank, and head to Millar for a bore, new rod, squish mod and decompression valve install.
There are a couple bearings that look like they may have been spinning in the case but with the bearing installed I cant feel any slop. I will just install with some green loctite and hope for the best. Usualy bearings will start spinning in there bore when they become worn out and start to create an imbalace and vibrate.
So now for the ugly shit that I found! the bore for the shifter shaft in both cases are cracked and the bore is slightly elongated. The shifter shaft had a slight bend in it that I was able to straighten out nicely. Has anyone run ito this problem and continue to use the cases without major issues?? Should I leave it as is? try to fix it? scrap the cases? Finding cr500 parts in Hawaii is practically impossible. I did run it thru all the gears prior to dissasembly and it shifted fine.
