Tips for splitting the case???

VenomMod

VenomMod

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Jan 11, 2007
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Houghton, Michigan
I'm in the process of splitting the case. I'm a bit scared since this will be my first complete tear down by myself. I'm having a hard time getting the magneto off. My puller just doesn't seem to cut it. Do I need just a bit more muscle? also there's two screws behind the mag that connect the two halves, they won't budge with the phillips screwdriver. What's the easiest way to get them out without damaging anything or the screws. Also what's the easiest way to split the cases when I get ready. I was told that there's usually a place to slip a bolt that'll go through one side to put pressure against the other to help with the splitting. I can't find any. Are they there? Also do I have to completely disassemble the water pump impeller? Sorry for all the questions, but I'm a bit nervous dipping down this far into a motor by myself and very little experience. Thanks for any input,

Drew :o|
 
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First off, youll need a automotive steering wheel/harmonic balancer puller to remove the flywheel, these have the strength to get them off, I use a 1/2" air impact on the puller and they "pop" right off, then behind the flywheel youll find 3 phillips head screws holding the stator to the cases. These must be removed, along with the 2 holding the wiring harness from the pick up coil. Go and get yourself a impact screw driver, its the only way you can get them out without destroying them, they are cheap, usually under $10, will come with multiple bits for phillips, straight blades, and some hex or torx depending on brand you buy. Once you have the flywheel and stator off and all of the lower case bolts off, youll see little indentations along the seams of the case, this is where you GENTLY pry them apart, it wont be anymore then a twist of the wrist on a large screw driver flat blade, like turning the screw, NOT driving the screwdriver between the case halves, the halves are precision machined and you dont want to nick the surfaces, this is why you only use a thin smear of yamabond on them for reassembly. If you have all the bolts out, it will come right apart,if it wont budge then you dont have all the bolts out.
 
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What kind of puller are you using? Those magneto's are on there pretty good and if you can get them off they come in a hurry. I just like to use a bearing puller. 3 claws that you can slip behind the magneto and one long bolt in the middle. When I pulled the flywheel off my SRX about a week ago, I had to use 1 wrench on the puller and another wrench on that wrench for extra leverage... when it popped off it almost got me in the face!

By the two screws behind the flywheel, I am assuming you mean the two screws with a thin peice of steel on the left hand side when facing the flywheel? If so, try hitting the end of the screwdriver hard with a hammer AS YOU ARE twisting it hard. This will sometimes break them loose. It is easier to get at them when you take the flywheel off and you can move the stator around a little to get at them better, you can sometimes get a pair of vise-grips on there and take them out that way once you get the stator/flywheel out of the way.

As far as splitting the cases, once you get everything out of the way (parts and bolts etc) they come apart pretty easily... or at least they mostly do... i've had a bit of a tough one before but it eventually came with a bit of effort. I have never seen a place to put a bolt in to take pressure on one half either and have never heard of this. If there is one there it sure would have saved a bit of effort though! Somebody else will have to chime in there.

You don't have to disassemble the whole water pump assembly... you just simply have to remove the water pump housing. Also, some of the motor mounts are holding the two case halves together. Make sure you get rid of those before trying to pull the halves apart.

Hope this helps a bit.
 
Thanks a lot, I'll pick up what I need tomorrow. Again sorry if I sound like a whiner or a little annoying, but I'm learning a lot. Trying to do it right the first time. Again thanks mrviper. I may of found some 700 cylinders I might have you port for me in the future.

Drew
 
It won't be a breeze, but you'll get through it. The first time is always the worst but if you take your time, remember where everything goes (I like to mock things up as they are removed whenever possible) and be careful you'll be just fine... the way i'm talking right now you'd almost think i'm an expert and old and wise... NOT TRUE! lol i'm no expert, the only wisdom I have is my teeth (which they will be removed anyway) I was at your stage this time last year!

Good luck!
 
Get your hands on a service manual, there is a little more to it than what can be told to you in a paragraph or two. One thing you may discover is that you need to add 2 stroke oil to a chamber in the case where the waterpump/oil pump drive is. You do need the impact screw driver. In removing the flywheel put tension on the puller and give the bolt a sharp rap with a hammer, often it will pop off then. An impact driver works well also.
 
you can simply add the oil with the oil pump removed from the case, thru the bearing, pretty simple. All in all the whole thing is in that paragragh or 2, not rocket science here.
 
You're instructions Mrviper were perfect. I did all that you described and in a matter of 15 minutes I had that case apart. Worked out great. Thanks for the help.
 
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