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**sharpy** · 04-28-2004, 03:44 PM

cases

have a look in the book and see if there are screws behind the clutch as on the 1000 motor and there might be a nut near the front sprocket as well. No t to much force is required to split the cases.

**TheBigRed** · 04-28-2004, 03:47 PM

got them

Yeah, I've got all those, clutch is totally removed, everything basically. I guess I'll go have another look here, but I"m 99% sure they've all been removed..

Ok, now it probably doesn't help that I removed the bolts etc on Monday night, but now that I look at it. the one "bolt" by the front sprocket that I removed was actually a nut on a stud. Might it be that I have to remove that stud? If so I guess I'm going to have to go out and get another nut to match the one I removed, then lock them on and try to turn the stud out. Hopefully that isn't the case cause I dont have any time tonight.

Amos

have a look in the book and see if there are screws behind the clutch as on the 1000 motor and there might be a nut near the front sprocket as well. No t to much force is required to split the cases.

**Anonymous** · 04-28-2004, 10:02 PM

Ahhh ... splitting the GS550 engine cases...

Man, I spent hours whacking on my case halves with a rubber mallet. I also (even though you're probably not supposed to) used bolts to jack the case halves apart. If you look at the front and back of the engine, you'll see a little square "box" that spans the case halves. I put a bolt and nut in there, and used that to apply a *little* splitting pressure to the cases while I whacked it with a rubber mallet.

The back of my cases split easier than the front. It turns out that the dowel which guides the cases together was rusted, and that caused the front to REALLY want to stick together.

A WARNING THOUGH ... don't put much pressure at ALL on that bolt. You can snap the "jack mount" right off the case. I did that on my donor engine before I realized that one of the crank-case bolts goes in from the top. You know the one, right? The REAALLLLY long one?

Now that I've got my cases split, I'm struggling removing a stupid @*#^@^ machine screw holding the oil separator plate in place....

--Mitch[/i][/code]

**Dink** · 04-29-2004, 04:50 AM

Did you remove the bolts from under the starter motor?
What about the two inside the oilpan?
The plates that are screwed in behind the clutch basket?
Dink

**TheBigRed** · 04-29-2004, 05:50 AM

Yup, got them

Yeah, I got that one. Pretty much been following the Clymers by the book.

Mitchn said:

A WARNING THOUGH ... don't put much pressure at ALL on that bolt. You can snap the "jack mount" right off the case. I did that on my donor engine before I realized that one of the crank-case bolts goes in from the top. You know the one, right? The REAALLLLY long one?

Yeah, I got all of those. Just to make sure though I'll check later today when I get home. I'll flip the engine back over and make sure I didn't miss anything else.

Dink said:

Did you remove the bolts from under the starter motor?
What about the two inside the oilpan?
The plates that are screwed in behind the clutch basket?
Dink

Amos

**TheBigRed** · 04-29-2004, 05:35 PM

Ok, now I'm stumped

Ok,
Upon further investigation I believe I do need to remove that stud.

Next question is how... :?

Not quite enough of it is sticking out for me to be able to get two nuts on it to tighten together to pull it, and the space in there is quite limited, so I'm at a loss..

Help

Amos

**Anonymous** · 04-29-2004, 07:11 PM

I split my cases with the stud near the output shaft still in place. I don't believe that needs to be removed. Unless it's too corroded and is holding things together... which I hope is NOT the case...

I can take a picture of my split cases tonight or tomorrow morning for you, so you can see the stud still in place, if you'd like.

--Mitch

**Hoomgar** · 04-29-2004, 09:04 PM

Originally posted by Dink

Did you remove the bolts from under the starter motor?
What about the two inside the oilpan?
The plates that are screwed in behind the clutch basket?
Dink

Amos, I think Dink has it. I remember seeing those behind where the clutch basket was and wondering about them. Those screws I asked you about, I'll bet they are the culprit.

**TheBigRed** · 04-30-2004, 05:56 AM

I'm not sure..

I'm not sure on those. If they are the ones I"m thinking about clymers said they only needed removed if you were going to access the shift fork shaft for maintenance to it.

If you aren't going to Philly Saturday I'm planning on getting some work in the morning as Jodi is busy.

Let me know.

Amos B.

**Hoomgar** · 04-30-2004, 12:47 PM

Re: I'm not sure..

Originally posted by TheBigRed

I'm not sure on those. If they are the ones I"m thinking about clymers said they only needed removed if you were going to access the shift fork shaft for maintenance to it.

If you aren't going to Philly Saturday I'm planning on getting some work in the morning as Jodi is busy.

Let me know.

Amos B.

I have no weekend plans and should be available.

**TheBigRed** · 05-02-2004, 01:23 PM

Success

Well, didn't get a chance to post this yesterday, but I"ve been successful in splitting the cases. As mitchn said those tabs were what did it. All the bolts had been removed, it just needed a little coaxing with those tabs. When I got the first one (the rear) to break the seal I was a bit scared at first. but then realized the slight pop I heard was the seal between the cases releasing.

Now it is on to replacing the transmission. I had noticed my "donor" transmissions drive shaft was a bit stripped where the front sprocket attaches. So, I'm going to have to remove all the gears from that drive shaft to put them on the one currently in mine since it is in better shape. I'm really hoping that this takes care of my second gear slip problem, even though a visual inspection doesn't look like the dogs are in that bad of shape, and the shift forks also don't look worn. I guess time will tell.

Anyone have anything else I might want to look at around there that might be the cause of my second gear slipping problem??

Amos

Originally posted by mitchn

Ahhh ... splitting the GS550 engine cases...

I also (even though you're probably not supposed to) used bolts to jack the case halves apart. If you look at the front and back of the engine, you'll see a little square "box" that spans the case halves. I put a bolt and nut in there, and used that to apply a *little* splitting pressure to the cases while I whacked it with a rubber mallet.
--Mitch

**Hoomgar** · 05-03-2004, 10:44 AM

Just want to hop in here and say what a heal I was on Saturday.
I told Amos I would be available to help him split the cases and then
stood him up because I had prior obligations I forgot about.

So feel free to send the birds of wrath to crap on my windshield for
standing up a fellow GS'r

:roll:

:P

Sorry bro, next time for sure, I'll check first. Felt like a heal.

**TheBigRed** · 05-03-2004, 02:24 PM

No worries man..

Not to worry about it... Now I'll just expect my rolling chassis to be down to the frame by Saturday so that it can be de-greased and roughed up to start the por-15 paint job. j/k

Seriously though, Jodi is busy tomorrow night if you want to come over for a bit and lend a hand I'm sure we could manage to get some more of the project done.

Then Saturday We'll see what we can do about getting you 1000 ready to accept the engine.

Unfortunately Money is becoming a little tight on my end. However I think I've got everything we'll need to get the engine back up to a running state. (darn broken leaf spring on my truck) :x

Amos

Originally posted by Hoomgar

Just want to hop in here and say what a heal I was on Saturday.
I told Amos I would be available to help him split the cases and then
stood him up because I had prior obligations I forgot about.

So feel free to send the birds of wrath to crap on my windshield for
standing up a fellow GS'r

:roll:

:P

Sorry bro, next time for sure, I'll check first. Felt like a heal.

**Hoomgar** · 05-03-2004, 03:31 PM

Re: No worries man..

Originally posted by TheBigRed

Not to worry about it... Now I'll just expect my rolling chassis to be down to the frame by Saturday so that it can be de-greased and roughed up to start the por-15 paint job. j/k

Seriously though, Jodi is busy tomorrow night if you want to come over for a bit and lend a hand I'm sure we could manage to get some more of the project done.

Then Saturday We'll see what we can do about getting you 1000 ready to accept the engine.

Unfortunately Money is becoming a little tight on my end. However I think I've got everything we'll need to get the engine back up to a running state. (darn broken leaf spring on my truck) :x

Amos

Originally posted by Hoomgar

Just want to hop in here and say what a heal I was on Saturday.
I told Amos I would be available to help him split the cases and then
stood him up because I had prior obligations I forgot about.

So feel free to send the birds of wrath to crap on my windshield for
standing up a fellow GS'r

:roll:

:P

Sorry bro, next time for sure, I'll check first. Felt like a heal.

That would be a go but tonight is out. I am committed to a few projects I promised done by tonight. I'll get with you later on the week maybe if it works out for you.

We have had a few water/weather issues that need fixing here as well as a shed door that is ready to fall off.

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Splitting cases.. help...

Splitting cases.. help...

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