Maintenance & Technical > KX250 / KX125

Splitting cases?

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ihampson:
Hi. Does anybody have any tips?   This is the first time i have done it. and could really use some help. I have read through the manual and have taken my time to try and do everything right but i can`t get them apart!

I am using a puller and have undone every bolt (i think!)The cases split about 1mm all round and are free to move on the locating pins. It feels as though it`s stuck on the crank. The only bolt i havent undone is on the selector drum. in the manual it says it will slide through the case on the clutch side. The engine doesnt appear to have been rebuilt for a while so could the bearing be stuck on the crank and in the case? In the manual it says the puller should only need to be tightened hand tight to seperate. I have tightened the puller as much as i dare (more than hand tight) and no joy! Is there some hidden away clip or bolt i have missed, or do i just have to keep tightening?

Dutch-K5 Fan:
If you have a manual, and done the proper instructions. Maybe a smal hit with a synthetic hamer or pice of woud on the crank axle should work. First put the nut back on for safety of damaging the thread.
Tightening it a bit, repeat above.
If it works and you are rebulding the engine. Put the crank and crankbearings in a plasticbag with some olie, and put it in the freezer. With a paintstripper/ gunheater/ hairblower warm up the case were the bearing fits.
So you don't have to hamer it back together, its muts beter for you engine/bearing!
And the engine wil run like new or better!!!

        Dutchie

ihampson:
Thanks for you reply dutch. I managed to get the cases apart. Tried the hammer,  heating it up, swearing at it, kicking it . . .  Finally got a better puller that mine, closed my eyes and tightened it down untill it came apart with a loud pop/ It mustn`t have been taken apart for ages. Thankfully after that everything was pretty easy and is all stripped down waiting for me to pick up the new bearings etc.

Kawasakinut:
           well i'm going through the same thing now. finally got the scratch to buy parts and have been picking up tools along the way the only tool i'm missing is the case splitting tool. i figured that i could get it  apart without one but no luck. i start buying goodies this week sweeeeeeeeeeeeeeeeeeeeeet can wait to ride!!!!  i'm picking up a cheap hydrulic press from harbor frieght any suggestions on what tonage i should buy?

don46:
I don't use a press to put the bottom end back together. I put the crank bearings in the freezer, after the've been in there for quite awhile, I install the seals, then heat the case, being very careful not to damage the seal, once it's hot, go to the freezer and drop a bearing right in. After both sides are installed into the case, i apply 2 stroke oil to the bearing on the clutch side, then heat up a metal slug, or a socket, something with some mass, and I mean heat it up, then set it on the inner bearing race and leave it for about 5 minutes, then take your crank and slide it right through the bearing. The repeat the process for the other side, once the slug is on the bearing I install the tranny shafts, shift forks and put my yamabond on the case half, I have a Kawi crank tool, so I put in between the crank halves and slide the left case right over the crank, it should slide right on, and once its seated completely i'll install the bolts and tighten it down. sometimes the crank isn't quite centered in the cases, with the crank tool installed you can give it a tap to center it and your good to go. the puller to split the cases is probably one of the most critical tools, in most cases the motor hasn't been apart and can be a bear, but with the right puller they come apart easily, Motion Pro makes a good one.

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