SuzukiSavage.com - Splitting the case ....What do I need to know?

gdrseeker

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Splitting the case ....What do I need to know?
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.

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1996 Savage, Jardine, K&N, 145 / 55 jets, 1 turn out at 5000 ft. elevation.

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paulmarshall Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1268 Carterton,New Zealand Gender:	Re: Splitting the case ....What do I need to know? Reply #1 - 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.
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paulmarshall Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1268 Carterton,New Zealand Gender:	Re: Splitting the case ....What do I need to know? Reply #2 - 04/28/13 at 11:08:22 Page 130 onwards of the Workshop Manual.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Splitting the case ....What do I need to know? Reply #3 - 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,,
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paulmarshall

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Re: Splitting the case ....What do I need to know?
Reply #4 - 04/28/13 at 11:55:57

justin_o_guy2 wrote 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,,

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.

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gdrseeker Senior Member Offline Addicted!! Posts: 365 Carson Valley NV	Re: Splitting the case ....What do I need to know? Reply #5 - 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.
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justin_o_guy2

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Re: Splitting the case ....What do I need to know?
Reply #6 - 04/28/13 at 12:04:23

paulmarshall wrote on 04/28/13 at 11:55:57:

justin_o_guy2 wrote 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,,

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.

Interesting project, wish you the best. Hope you both get thru your projects smooothly,,

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The people never give up their liberties but under some delusion.- Edmund Burke.

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paulmarshall Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1268 Carterton,New Zealand Gender:	Re: Splitting the case ....What do I need to know? Reply #7 - 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?
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Dave

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Re: Splitting the case ....What do I need to know?
Reply #8 - 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.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Splitting the case ....What do I need to know? Reply #9 - 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
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paulmarshall

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Re: Splitting the case ....What do I need to know?
Reply #10 - 04/28/13 at 12:34:12

Dave wrote 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.

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

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paulmarshall Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1268 Carterton,New Zealand Gender:	Re: Splitting the case ....What do I need to know? Reply #11 - 04/28/13 at 12:43:48 Dave have you split the cases before?
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paulmarshall Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1268 Carterton,New Zealand Gender:	Re: Splitting the case ....What do I need to know? Reply #12 - 04/28/13 at 16:11:44 I figured out how this this would work.
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paulmarshall Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1268 Carterton,New Zealand Gender:	Re: Splitting the case ....What do I need to know? Reply #13 - 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?
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Dave

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Re: Splitting the case ....What do I need to know?
Reply #14 - 04/28/13 at 18:01:49

paulmarshall wrote on 04/28/13 at 12:43:48:

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

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Someday I will be old......But not today!

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