splitting case on a 03 kx250

[razornpc]

do i need to use a case spreader or should i try a rubber hammer and start tapping?

[stewart]

spreader

[Viston]

Please save yourself alot of frustration and damage it is well worth the cost of the proper tools! Cases, cranks, and rods, are fairly robust and take alot of abuse in a normal running engine.

However they are VERY prone and EASY to damage with the use of hammers, screwdrivers and what ever else one with out proper tools uses to split your cases. Do the right thing get the spreader or borrow one.

[Friar-Tuck]

   Case Splitter
http://www.rockymountainatv.com/productDetail.do?navType=type&navTitle=Tools%2FShop&webTypeId=140&webCatId=22&prodFamilyId=17167
  Tuck\o/

[razornpc]

ok i know im going slow but how do i get the shift cam off? just engage it and turn to the left?

[Friar-Tuck]

 It should pull out with the shift forks and shaft.  I don't know that a 250 would be any different design than the 500's or not, sorry...
  have you already got the cases apart?
Tuck\o/

[razornpc]

nope, like i said im moving slow. the manual i have says to pull it out but it looks to me like it would come out like your saying, with the case half. also in the book it shows a T-bar puller, that would be better then me buying a case splitter since i have 1 of those already.

[The Flyin Hawaiian]

If your talking about the shift star, on the clutch side, it unbolts from the shift drum. The drum cant be removed w/o splitting the cases. Dont lose the centering dowel pin underneath the shift star.

[razornpc]

so its super tight, just keep turning and it will break loose?

[The Flyin Hawaiian]

Im pretty sure its loctited from the factory.