Case splitting.

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Case splitting.

Postby scheckaet » 09:50 pm Feb 19 2013

no i'm saying the 2 halves MUST be the same distance from each other all around and not pinch/bind the rod.
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Case splitting.

Postby dgraver1 » 11:19 pm Feb 19 2013

I really appreciate the help you guys are giving me. I just don't have anyone to get advice from. So thanks!
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Case splitting.

Postby dgraver1 » 10:24 pm Mar 28 2013

Got around to splitting the cases again. also took out the whole trans and crank. Shift forks seem to be just fine, so i dont think that they were being pinched. I am having a shop take a look at the crank to make sure it is within its specs. hopefully that turns out well.

Also took the case halves to the shop because I need to have them pull out the crank bearings for replacement and I noticed something a little odd with the halves. I took a picture to show what it is.

ImageImageImage

The guys at the shop said it looks like this came this way from the factory. Id like a couple more opinions on that. My idea was when I put the halves together, these stress fractures are a result of whatever was binding in there.
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Case splitting.

Postby rbates9 » 10:32 pm Mar 28 2013

I think the little cracks you see are kinda normal for cheap castings. I have seen them before on brand new parts that have never been assembled. Clean everything up and slap it back together. You should be fine.
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Case splitting.

Postby scheckaet » 11:52 pm Mar 28 2013

relax. not cracks but casting marks.
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Case splitting.

Postby dgraver1 » 12:10 am Mar 29 2013

Sounds good. I will hopefully have my little kdx back together within 2 weeks.. And to the OP I really apologize for jackin your threads so much.. But hopefully someone else will learn from it.
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Re: Case splitting.

Postby frenche200 » 08:20 am Feb 01 2014

Great topic! Excuse me if the question already been asked, but my feeble understanding of English make me some trouble to reading ..
I see you put the bearing in the half case first, and not on the crank: a particular reason?
thank you :grin:
i'm French and I don't speak English very well, so, please, excuse me :)
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Case splitting.

Postby scheckaet » 12:59 pm Feb 03 2014

easiest way that i know.
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Re: Case splitting.

Postby Tedh98 » 01:00 pm Mar 22 2014

rbates9 wrote:Image


Quick question/clarification on the crank installer. Does the base of the installer rest against the case or does it somehow rest against the inner bearing race?

I would think it has to rest against the case, otherwise the seal would be in the way and get damaged if the installer rested against the inner race. But if it rests against the case, it would cause a side load on the bearing when you crank is pulled through.
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Case splitting.

Postby rbates9 » 01:15 pm Mar 22 2014

yes. It sits against the case. It does side load the bearing but the bearing should be hard enough to not be harmed by it. Pretty much any way you put the bearing in will side load the bearing.
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Re: Case splitting.

Postby Tedh98 » 01:04 pm Mar 23 2014

Thanks for confirming that.
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Case splitting.

Postby DJNiedz » 08:54 am Sep 05 2015

i had the spare time, lathe, and mill. I made my crank installer rather than spending the money. worked like a charm (on my friends yz125, havent used it on my kdx yet, probably this winter).

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Case splitting.

Postby scriberman » 01:46 pm Oct 29 2015

rbates9 wrote:yes. It sits against the case. It does side load the bearing but the bearing should be hard enough to not be harmed by it. Pretty much any way you put the bearing in will side load the bearing.

Big engineering NO NO to side load ball bearings . I remove the crankcase lip so I can install the bearing correctly. Also means crank seals can be replaced without splitting cases. Plus plus.
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Case splitting.

Postby Tedh98 » 03:31 pm Oct 29 2015

scriberman wrote:Big engineering NO NO to side load ball bearings . I remove the crankcase lip so I can install the bearing correctly. Also means crank seals can be replaced without splitting cases. Plus plus.


Do you have pictures of the retainers you setup to replace the lips you removed?

I was going to attempt this on an extra set of cases but couldnt see bow to securely fasten a retainer.

I have found heating up the inner race is the way to go.
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Re: Case splitting.

Postby scriberman » 05:17 pm Oct 29 2015

No retainer needed. Seals are a nice fit in the cases , smear of wellseal is all thats needed. Most modern stuff just press fits from the outside. Done 3 engines so far, all running well.
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Re: Case splitting.

Postby TurboLS » 09:36 pm Jan 04 2016

Does anyone who has the tusk tools want to lend them out for free or a fee (plus a deposit)?
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Re: Case splitting.

Postby kawi_rider » 06:40 pm Jan 06 2016

Ok guys i have a question myself it may sound stupid but i cant find out how to make a post can someone please teach me how? :hmm:
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Re: Case splitting.

Postby riknull » 12:16 pm Apr 06 2016

A million thanks to rbates9 for the post and photos, they were a tremendous help while replacing crank seals on my motor.

However, I made a boneheaded mistake which I hope to help others avoid--I left 2nd gear off the input shaft and pressed the case crankcase together. When checking the trans through all the gears afterward, 2nd acted like neutral (no kidding!) and several gears seemed to be the same ratio. Without that gear in place, the input shaft could slide left and right within the cases.

All told it cost me a couple of days and $30-ish for a new left side crank bearing. The bearing stayed with the crankshaft when I took it apart, and I didn't feel comfortable putting it back in after being pressed off the crank. Pay attention, focus on your work, and don't do what I did!
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Re: Case splitting.

Postby Tedh98 » 10:01 am Apr 07 2016

riknull wrote:However, I made a boneheaded mistake which I hope to help others avoid--I left 2nd gear off the input shaft and pressed the case crankcase together. When checking the trans through all the gears afterward, 2nd acted like neutral (no kidding!) and several gears seemed to be the same ratio. Without that gear in place, the input shaft could slide left and right within the cases.


To help others who are using a puller to put the cases back together, don't install the left seal and bearing in the left case. Install the right seal and bearing and pull the crank into the right case. Install the transmission and since you don't have a bearing in the left case, you can slide the left case in place and snug down a few case bolts. Now you can run through the gears and test to make sure the transmission is installed properly.

Once you verify that, install the left seal and crank bearing then use your puller to bring the cases together.
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Case splitting.

Postby oldgoat1948 » 02:24 pm Aug 11 2016

Thanks a bunch, I'm in no mans land, and I'm going to split the case this weekend. I have never tore down a 2 stroke before.
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