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How To: Splitting engine without removing top-end

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FT500R:
Closing the engine
Closing the engine again is not that hard but it is a bit fiddly. Your best bet is do some ‘dry’ practice runs without any sealant first to get the hang of it.
This was my method:
Install all 3 set rings on the bearings and not in the lower engine case.
Install the 2 dowels that will go into the bearings in the lower casing and tilt two bearing holes slightly towards the back of the engine (really slightly probably only 1 or 2 degrees).
Make sure the shift forks are in the correct spot on their shafts so the ends fit in the shifter drum.
Apply a thin layer of sealant on the edges of the lower cover. (First try a couple of times without sealant to get the hang of it)
Gently position the lower engine casing with the back-of-the-engine side on the upper casing, keeping the front-of-the-engine side lifted up so you can look down into the engine.
Sideways align the 3 shifter forks with the gears on the primary and secondary transmission shafts.
Now gently close the engine casings by lowering the front-of-the-engine side of the lower casing. The two rear shifter forks will automatically fall in the correct slots between the gears, you can check this through the sump hole.
 
The most forward shift fork needs some help to slot into the correct place, take a long thin object and push the shift fork a bit forward so it can seat correctly while you further lower the bottom engine casing.
The two halves should now rest evenly on each other, there might still be a small gap because not everything immediately seats perfectly.
Gently push down or lightly tap the bottom half to seat it further, don’t force it down, if you need to force it you need to start again because something is misaligned.
 
A gap like the one in the picture should close when you push on the bottom case and/or hand tighten the casing bolts.

Put the 4 main crankcase bolts in but only screw them in hand tight. (this should definitely close all gaps)
Check if you can still turn the output shaft easily (gearbox needs to be in neutral)
Flip the engine over and install all engine casing bolts torqueing them as described in the manual.
Flip the engine back upside down to install and torque all bottom engine casing bolts.
Install the automatic balancer spring and bolt.

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