I am seeing I need a fly wheeler puller and about 3 other specialty tools.
Lots of info here, both good and bad.
The new case you ordered from Honda will come with all the bearings pre-installed. You will
need to purchase seals and retainers and, as somebody already pointed out, a complete gasket
kit (more cost effective than purchasing individual gaskets).
Since this is a ten year old tiddler, I recommend you replace all the circlips, shift pawls, shift pawl
springs, gearshift spindle spring, gearshift ratchet spring, right side crank bearing and all the seals
on the right side case. This will essentially yield a like new feel (shifting action especially), for the
bottom end.
Before you start, I highly recommend getting a Honda Service manual. There is a lot of useful
info, including seal depths, that isn't found in other manuals.
For tools, you'll need a flywheel puller and case splitter. There are many other ways to accomplish
these two task, but I don't recommend them on your first attempt. A good but inexpensive line
of tools is the Tusk brand sold by Rocky Mountain. They also sell a crankshaft puller/installer
that is very useful for this job.
I recently posted an engine tear down and rebuild pictorial using a CR500 engine on anther forum.
The basics are the same and the pictures and techniques might be helpful. Here is a link if you are
interested:
http://www.allthingsmoto.com/forums/f-235/cr500-engine-build-pictorial-part-1-a-50432/Good luck with it.
dogger
