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General Category >> Rubber Side Down! >> Splitting the case ....What do I need to know?
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Message started by gdrseeker on 04/28/13 at 10:17:43

Title: Splitting the case ....What do I need to know?
Post by gdrseeker on 04/28/13 at 10:17:43

So I am splitting the case on this engine I have for parts. (The top end is trashed but the bottom end still has lots of good parts.)

I found directions in Clymers but they are difficult to follow as usual. anything I need to know as I proceed with this project? is there a tech guide to doing this her eon the forum? I searched but did not find anything.

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 10:34:37

I too looked in the Tech section for this info but couldn't find anything.
gdrseeker can you document/photos as you go please, I will do the same.

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 11:08:22

Page 130 onwards of the Workshop Manual. :)

Title: Re: Splitting the case ....What do I need to know?
Post by justin_o_guy2 on 04/28/13 at 11:50:47

Well,, since its "For Parts" & youre not doin a rebuild,, SHOULD things say, ohh,, Not Go Well, youre not gonna lose much, but youll learn something,,

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 11:55:57

485751564B4C7D4D7D45575B10220 wrote:

Well,, since its "For Parts" & youre not doin a rebuild,, SHOULD things say, ohh,, Not Go Well, youre not gonna lose much, but youll learn something,,

gdrseeker is not rebuilding however I am. Which is why I would like him to go first.
I am planning on replacing the 400 crank and Rod with gdrseeker's 650.
This might not work, wont know unless I try.
Worse case scenario is put it back together as a 400. :)

Title: Re: Splitting the case ....What do I need to know?
Post by gdrseeker on 04/28/13 at 12:00:12

Already started but I will try to get photos from here. And document stuff. I might be able to jack track a bit .

And yes I am getting great experience ....learning a lot with no risk of ruining my actual engine on my bike. I will be able to go into it with confidence layer if needed.

Title: Re: Splitting the case ....What do I need to know?
Post by justin_o_guy2 on 04/28/13 at 12:04:23

1302160F0E0211100B020F0F630 wrote:

[quote author=485751564B4C7D4D7D45575B10220 link=1367169463/0#3 date=1367175047]Well,, since its "For Parts" & youre not doin a rebuild,, SHOULD things say, ohh,, Not Go Well, youre not gonna lose much, but youll learn something,,

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 12:04:25

On page 132 of the workshop manual they mention a special tool (part No. 09930-324100 to remove the flywheel nut. Can this tool be fabricated at home?

Title: Re: Splitting the case ....What do I need to know?
Post by Dave on 04/28/13 at 12:24:44

There are several tools that you will need....most of them for the left side. The magneto rotor needs a special puller. It is a tapered shaft on the crankshaft and you need a puller that fits over the threaded portion of the rotor and pushes on the crank with the center threaded rod on the puller. (This rotor is very tight and I have no idea how yo could get it off without a puller). The flywheel nut is big and 100 foot pounds tight...you need both a large deep socket and a holder for the flywheel.

On the right side the gear on the crankshaft can be tight and you need a puller, and the clutch nut often needs something to hold the clutch basket....but for removal an impact wrench will get it off.

You may also need to adapt a puller to fit on the right side to pull the case halves apart evenly.....the bearing on the crank and the clutch shafts are snug and will drag as you try and seperate the two halves.

Title: Re: Splitting the case ....What do I need to know?
Post by justin_o_guy2 on 04/28/13 at 12:27:30

Looks to me like "Where" is gonna be about as important as anything. Lousy access ( On the floor) is gonna make it harder

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 12:34:12

576C6176676B70766D656877040 wrote:

OMG this sounds harder and harder. I am a determined Kiwi that likes a challenge, I hope gdrseeker is up for a challenge too. :-/

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 12:43:48

Dave have you split the cases before?

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 16:11:44

I figured out how this this would work. :)

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 16:14:25

But this thing has got me thinking :-/ It fits over a socket and then what? Is there a hole in the other end? :-[ It looks like its made of plastic.
Wouldn't any 46mm long reach work?

Title: Re: Splitting the case ....What do I need to know?
Post by Dave on 04/28/13 at 18:01:49

2233273E3F3320213A333E3E520 wrote:

Dave have you split the cases before?

Yep...my engine developed a knock and had to come apart to find it. It ended up being the left crank bearing and a loose flywheel. Here is the thread:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1342319094/0

I had to buy the mag puller, I made a deep socket from a normal one by cutting it in two and welding in an extension, and I made a holder for the flywheel and clutch.

Dave

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 18:13:59

457E7364757962647F777A65160 wrote:

[quote author=2233273E3F3320213A333E3E520 link=1367169463/0#11 date=1367178228]Dave have you split the cases before?

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/28/13 at 19:05:31

Here is the Magneto puller I will need.

Title: Re: Splitting the case ....What do I need to know?
Post by Dave on 04/30/13 at 05:33:17

Here are the pictures of the tools I used. The mag puller I bought from an eBay seller, it was about $ 80. The large socket was made by purchasing a cheap socket at Tractor Supply, then cutting the hex section off the 3/4" drive section and welding in an extension. The flywheel holder was made from angle iron and an old 1/2" drive deep socket. The clutch holder is the wooden board with the metal tabs......I was getting tired of making tools by the time I got to this point.......it look crude but it holds the clutch basket just fine.

Title: Re: Splitting the case ....What do I need to know?
Post by paulmarshall on 04/30/13 at 11:03:11

Thats Dave for supplying those pics. :)

Title: Re: Splitting the case ....What do I need to know?
Post by kojones on 05/04/17 at 03:52:21

So, what is the best order to remove parts before splitting the crankcase?

I was thinking that I start from the left side, removing the magneto rotor and flywheel first, then the right side crank nut, clutch basket and finally the pulley nut before lifting the engine off the frame. This way I could use the rear brake as counter force.