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Help with splitting tight centre cases.

Joined Feb 2008
72 Posts | 0+
NSW Australia
I have just come to seperating the centre cases on my 02 - 03 FE400E and am finding them very tight. I still have the flywheel in place as I am waiting on a puller but thought I would remove the righ case from the left so I can find where the metal is coming from. I have checked and double checked all screws undone. After much effort I have them apart about 1mm and they appear to be very tight on the crank as you can see that is the point which is holding them. I have a plate with a bolt that I use on Huskys and most Jap bikes that push the crank out but my Berg bent it. Are they usually this tight ?
Cheers Dan
 
Danielson said:
I have just come to seperating the centre cases on my 02 - 03 FE400E and am finding them very tight. I still have the flywheel in place as I am waiting on a puller but thought I would remove the righ case from the left so I can find where the metal is coming from. I have checked and double checked all screws undone. After much effort I have them apart about 1mm and they appear to be very tight on the crank as you can see that is the point which is holding them. I have a plate with a bolt that I use on Huskys and most Jap bi
kes that push the crank out but my Berg bent it. Are they usually this tight ?
Cheers Dan

I dont know exactly what you mean, but I think there is bolts under the flywheel, so you must take that out first.

Regards
 
There are no bolts under the flywheel as they have nowhere to go. I know this is not the usual way to seperate the cases but I can see no reason as why it should not be possible.
I am keen to see where the metal flakes are coming from and rectify it so I can ride again.
Cheers Dan.
 
So if I understand you correctly, rather than doing the commonly used practice of removing the RHS case half (flywheel side) first, you are leaving the flywheel on due to lack of a puller but attempting to remove the LHS case first??
 
That is correct and I have done it many times when dismantling other bikes as I run a wrecking yard. Problem seems the berg is real tight. I will remove the flywheel at a later stage and reasemble in the correct order. I just really wanted to get it apart and find where the metal flakes are coming from.
Cheers
 
My mistake, I was thinking about 04-newer case, they got a bolt beside the flywheel. I personaly missed that one when a shoud pull my cases apart :roll:
Mayby you have ballbearings in that engine, and the fitt off those are holding, So you need a case splitter, but then you need the fly off.

Regards
 
there is a bolt that can be missed in the middle of the cases as opposed to all the way around the outside. it's near the oil filter housing.

regards

Taffy
 
Thanks I was looking at the manual I downloaded and did wonder whether I fully removed the bolt near the filter housing. I wll check it when I am at the workshop next and be humble if I have not removed it all the way.
 
Made my own plate to split the cases, they came apart with very little force. I just put a little bit of pressure on the bolt on the crank case and then tapped the swingarm hole with a wooden hammer until it popped open a bit, repeated this a couple of times and off she came.

208633237.jpg


And due to a little unavoidable mishap during flywheel dismanteling :D :evil: :D , I had to order a proper flywheel puller and had to wait a couple of weeks for it to arrive, so I went ahead and pulled of the other side first. No problem with that so that's not the source of you problems.

206170799.jpg
 
Danielson said:
Thanks I was looking at the manual I downloaded and did wonder whether I fully removed the bolt near the filter housing. I wll check it when I am at the workshop next and be humble if I have not removed it all the way.
Have you removed the two bolts that holds the oil filter cover?And the bolt above the oil drain plug?
 
I have been away for the Easter break and have only had time to do a quick check and yep I I have checked again that ALL twelve 6mm screws are out + the two 5mm oil filter screws, the one above drain plug and in front of clutch slave is definately out. I will make a new new puller out of some heavier plate as I think it may have bent due to the fact it has been drilled to fit many different bikes over the years and has lost to much metal.
Thanks for all the replys will persever when time permits.
Regards Dan
 
I recommend pulling the flywheel, and then pulling the right case off. Everything stays in place much better when done this way (all parts sit in the left case).
 
O.K got it apart with a new improved puller made from much heavier plate. I cannot find a faulty bearing although most feel not as smooth as like so I am replacing them. Counter balancer is of the singe bearing type which I have a new bearing for. I do have the later double bearing style out of a 03 650 which I could modify to fit but at this stage have opted for the original. The only place I can see where the metal flakes have come from is the actuating lever on the kickstart decompressor. When the kickstarter is on its return stroke it has a ramp on the back which pushes the spring loaded shaft to the right of the motor. On mine it is gouging pieces of metal away that I presume are going through the gearbox and being flattened to resemble metal flakes that look just like hard facing. So I probably could have saved myself a motor tear down but at least I know it will be good.
Thanks for the support and keep this in mind for other users.
Cheers Dan
 

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