I split the cases on my 2002 650, without much prior experience in engine work. Worked a lot on cars and bikes before but never any major engine work. I made some stupid mistakes, but in the end I got it back together and even got it to start, due to lack of time I have not completely finished the bike, thus I have not ridden it.
Do a search on my user name and you will find about a million topics, filled with desperate cries for help, wich the guys on this forum have helped me with every single one!
This forum combined with the service manual and the parts list will guide you through any problems when rebuilding.
Some tips and mistakes that i made:
- Use a proper fly wheel puller, and not a three arm puller, even tough there are three slots in the flywheel where the three arm puller fits in, use a proper puller, since apparantly these slots are for putting a three arm puller on the flywheel to lock the crank in TDC when setting the cam.
If you do use a three arm puller, this is what will happen:
- For actually splitting the cases and pressing out the crank Husa offers a special tool, I kinda copied it, it looks crude but works a whole lot better than trying to pry open the cases with a screw driver.
- Don't know if you are planning on removing the gearshift drum, but if you do, put it in neutral before disassambly and mark the drum and case so you know the right position when reassembling. I didn't do it, and had to assemble and split the cases a couple of times, trying different positions before I got it right.
- Do a search on this forum on axial play, or bearing float, this will give you a lot of info ont the crank axial float, wich according to very knowledgably people is one of the main reasons of main bearing failiure.
The last and most important tip, is when in doubt, use the search function on this site, about every single aspect of the Husa has been extensivly discussed on this forum. If you can't find it with the search, just ask (preferably with pictures) and someone will come along and help you!
