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    #1

    Screwed the pooch

    Help! I have removed the engine from the bike and have followed all the steps in the Clymer manual for removing the crankcases in order to easier clean the 35 years of road grime off of them and potentially powder coat them. I got to the the step of "lightly tapping" with a rubber mallet to separate the halves, however nothing will budge. I cannot get the halves to separate!!!

    To make things worse, in the process of lightly tapping, I cracked the lower crankcase of the clutch housing. I don't think frustrated quite cuts it at this point in time. Have I ruined the engine? Where to I go from here? Please give me some good news.
    Tags: None
    #2
    Clean it real good and have it welded

    Comment

      #3
      What bike is this????
      MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
      1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

      NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


      I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

      Comment

        #4
        Sorry, it's a 77 GS750. I kind of figured I could get it welded. Any suggestions on an easier method for splitting the crank cases?

        Comment

          #5
          In the front and at the back of the tranny, there are "notches" that the suzuki factory tool slipped in to pry the halves apart. You can put a wide blade flat tip in there and with a twisting motion get the halves to start seperating. Note that there are dowels that line up each half. You will need to use something that wont hurt the mating surfaces to shim it up as you gently pry them apart.

          Wood wedges work well to shim along and keep the gains youve made. Keep going back and forth and gently get them apart..try to keep them seperating evenly as to not bind them up on the dowels.
          MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
          1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

          NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


          I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

          Comment

            #6
            Originally posted by Havoc1231 View Post
            Sorry, it's a 77 GS750. I kind of figured I could get it welded. Any suggestions on an easier method for splitting the crank cases?
            Did you remove ALL the bolts that hold the two halves together?

            There is one under the starter motor, and I think one other that is relatively "hidden".

            .
            sigpic
            mine: 2000 Honda GoldWing GL1500SE and 1980 GS850G'K' "Junior"
            hers: 1982 GS850GL - "Angel" and 1969 Suzuki T250 Scrambler
            #1 son: 1986 Yamaha Venture Royale 1300 and 1982 GS650GL "Rat Bagger"
            #2 son: 1980 GS1000G
            Family Portrait
            Siblings and Spouses
            Mom's first ride
            Want a copy of my valve adjust spreadsheet for your 2-valve per cylinder engine? Send me an e-mail request (not a PM)
            (Click on my username in the upper-left corner for e-mail info.)

            Comment

              #7
              DO NOT pry on the mating surfaces with anything that will scar or do damage to them!!! IE:::Screwdrivers, pry bar, etc etc.
              MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
              1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

              NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


              I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

              Comment

                #8
                Reseal the cases with Three Bond 1207B..Buy it from an online source. My tube from Suzuki was ordered a month ago and was back ordered and wont be shipped till the first week of March!!!!
                MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
                1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

                NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


                I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

                Comment

                  #9
                  The other "hidden one" i suspect is the one in the front that comes up from the bottom right between the 2 and 3 exhaust ports?? That the one you mean Steve?
                  MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
                  1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

                  NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


                  I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

                  Comment

                    #10
                    there is the one inside the oil pan..by the pick up tube if I am remebering right.
                    MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
                    1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

                    NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


                    I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

                    Comment

                      #11
                      Sorry to hear of your mis-adventure with the case splitting. I've never worked on that motor so I couldn't tell you where any "hidden" bolts are: the ones from the 550 aren't there. Tapping got me nowhere with my crankcase either, so I used bolts in the notches that Chuck is talking about. Just a few turns got the halves apart easily once I had verified all the bolts were gone. This picture may help:



                      Good luck. You might want to post a pic of the damage. Also, check out the crankcase parts fiche as it shows the location of all the bolts:

                      Comment

                        #12
                        Mike, thanks, that visual definitely helps out. I'm fairly certain I have removed all of the bolts. The only one I havent' compltely removed is the one that's blocked by the oil filter cover stud which I couldn't get out. I did loosen that bolt though and I'm pretty sure it's unthreaded, just not removed. I tried removing the aforementioned oil filter stud via the "double-nut" method, however I think all I accomplished was tearing up the threads of the stud and permanently affixing a nut to it's base.

                        Also, I havent removed the pistons, because it wasn't a step in the Clymer manual (aka my Bible), but it seems to reason that I will need to do that in order to remove the cases..right?

                        Here's the damage:
                        http://i.imgur.com/AKO4Vux.jpg

                        http://i.imgur.com/ynfohZ3.jpg


                        Thanks for all your help thus far.

                        Comment

                          #13
                          With the psitons off the rods, they dont get snagged at the bottoms and cause you any hangups. Put your hand over the circlips as you remove them from the slot so they dont go flying across the garage somehwere and get lost.


                          The local welding shop can easily TIG that crack for you..be glad it didnt snap a chunk off!!!!
                          Last edited by chuck hahn; 03-01-2013, 10:23 AM.
                          MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
                          1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

                          NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


                          I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

                          Comment

                            #14
                            Originally posted by Havoc1231 View Post
                            Also, I havent removed the pistons, because it wasn't a step in the Clymer manual (aka my Bible), but it seems to reason that I will need to do that in order to remove the cases..right?
                            Don't get me wrong, the Clymer manual is not bad, but your GS-working bible should probably be the factory service manual. The 3rd-party manuals contain some helpful views and tips that the factory manual won't, but I've also seen typos and omissions in them as well. They're best used as supplements to the factory service manual. You can download a PDF manual for your bike from BassCliff's site (did you ever get a mega-welcome?):

                            http://members.dslextreme.com/users/bikecliff/


                            That damage looks like a weld and some smoothing should take care of it.

                            Comment

                              #15
                              Originally posted by chuck hahn View Post
                              The other "hidden one" i suspect is the one in the front that comes up from the bottom right between the 2 and 3 exhaust ports?? That the one you mean Steve?
                              Each engine is different. I have not split any cases yet, so I don't have any personal experience, just relaying what I have read here.

                              .
                              sigpic
                              mine: 2000 Honda GoldWing GL1500SE and 1980 GS850G'K' "Junior"
                              hers: 1982 GS850GL - "Angel" and 1969 Suzuki T250 Scrambler
                              #1 son: 1986 Yamaha Venture Royale 1300 and 1982 GS650GL "Rat Bagger"
                              #2 son: 1980 GS1000G
                              Family Portrait
                              Siblings and Spouses
                              Mom's first ride
                              Want a copy of my valve adjust spreadsheet for your 2-valve per cylinder engine? Send me an e-mail request (not a PM)
                              (Click on my username in the upper-left corner for e-mail info.)

                              Comment

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