[maddvector]

I ended up having to tear my motor in half in order to replace the Bearing Housing Drive Bevel Gear Seat  in the transmission.

I decided to go through the engine since it is in half...

I can't get the magneto off. I have the 42mm magneto removal tool.

Is there another part that is between the nut & the magneto that has to be removed first?

[NMKawierider]

It takes this special puller to get the rotor off. Nothing else will work without the possibility of damaging it. If this is what you have then I too am at a loss except I know it has to push directly on the crank end and it looks like here is still something over it. On others you have to put the bolt mostly back in and leave a few threads out so the puller pished on the bolt head..nothing else. Maybe it's that way with this.

https://www.ebay.com/itm/174095132236?hash=item2888e0e64c:g:6UMAAOSwbF1aAjWg&amdata=enc%3AAQAIAAAA4P6q73zXWLJiFkuJWoZR1h2VdA0PeLgbm1fME3BFLal1pbP%2FlkVHIJLimLtSTlAtUbMd02sNgR5k3mr8GYAoEgvPmiQnryq6XSJS3TZRCUozsgp92ip0lyorz6B9%2F0Ifyppte99ZsSdufwIBqpqnWrDy2F90ERamvF5xQMSjT2Ss0V7mHbT%2Bt9J45KLkFxZqT4ExkDi4p%2FaQsWvPm5hWfyw2BglKAfaqpqUc1J%2BxTi90NxX4BCRq127XHXqDv41GGrbHnq2L%2B4hMobscw41MeHCHEtz%2FtihZD6OCgaJO3PpB%7Ctkp%3ABk9SR7yQ3MGXYw


WTF happened with the bearing housing?

[maddvector]

I purchased it with this problem but I'm at a lost to explain how someone busted the teeth off of the front wheel drive bezel along with busting the bezel seat...

They had to rev the engine up to max rpm's and throw it in gear...

This is the tool I purchased:
https://www.amazon.com/gp/product/B0C5X9VS9J/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

[NMKawierider]

Looks to be the right puller. Put the bolt in leaving about 1/8" of shaft exposed and try it. Its a wedge or taper fit and will take some to pop loose. It has to pull on the hub of the rotor and push against the crank shaft...on a bolt, not on the open hole. Bummer on the bevel gears. I know Chinese metallurgy is no where near the standards of ours and as such takes much less to cause failure. I know some that had shredded pinions from just the chattering of braking on a decel when the drive train starts kicking back and forth. In some applications the Chinese even uses compacted metal gears...although this one looks to be steel.

[maddvector]

Is this the Magneto Cover and do you remove it?

[NMKawierider]

The breakdown doesn't show that end but it does show one the retainer bolt goes through for the oil seal. It probably just pops off. In any way it either has to come off to expose the crank end or the retainer bolt has to be screwed back in some for the puller to push against the crank. If it comes off, do not allow the puller to make direct contact with the crank. Use the bolt as I said either way.


 

[maddvector]

NMKawierider

I appreciate the replies.

Apparently  the one on my machine is stuck, stuck, and stuck...

I sprayed it with PB Blaster.
Hopefully it will break loose!

[NMKawierider]

I'm thinking it has to be this sleeve that's over the end. Its used tor tightening the rotor, bearing and its the surface for the oil seal. Whatever you do don't hurt the seal surface but maybe a little side to side tapping will slip it out of it's landing on the rotor's hub.

[maddvector]

It finally slid off...

Thanks!

[maddvector]

Does anyone know if there is a difference between a crankshaft marked "A" or a crankshaft marked "B"?

I know they have different part numbers with different rod bearings.

Just wondering...

[NMKawierider]

Just from what I've been told the "B" version, the xx21 addressed a problem. What that problem was I don't know. It does take the new bearing but not sure if you can get the old bearings for the old crank..or what the difference is. Got to be a memo on it somewhere.

[maddvector]

I'm having problems getting my timing correct.

I've read post:  https://cfmoto-forum.com/800ex800/timing/

On my case there isn't a mark or divot where you line up the 2|T or the 1|T lines on the Magneto...

Any suggestions?

Thanks,

[NMKawierider]

I'm having problems getting my timing correct.

I've read post:  https://cfmoto-forum.com/800ex800/timing/

On my case there isn't a mark or divot where you line up the 2|T or the 1|T lines on the Magneto...

Any suggestions?

Thanks,

On pages 7-27 to 7-30 of the service manual it explains the timing procedure and how to lock #2 cylinder on TDC with the locking bolt. Although it doesn't talk about using the locking bolt on cylinder #1, I have to assume the process is the same. I mean why be able to lock TDC on one cylinder but not the other...right?

[maddvector]

A word of caution to all DIY mechanics...

Mark the wires that go to your front and rear coil packs when you are doing your tear down.
If  you reversed them;  it sounds like you have timed the motor incorrectly!

[NMKawierider]

A word of caution to all DIY mechanics...

Mark the wires that go to your front and rear coil packs when you are doing your tear down.
If  you reversed them;  it sounds like you have timed the motor incorrectly!

Ignition timing....