Splitting cases - Suzuki GSX-R Motorcycle Forums Gixxer.com
 
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post #1 of 4 (permalink) Old 05-24-2019, 06:06 PM Thread Starter
Squid
 
Join Date: May 2019
Posts: 4
Splitting cases

Hi all, I am in the process of replacing the upper half (cylinders) of a track 07 750. I have already removed all the internal and external bolts that are keeping the cases together and I am able to separate them... a bit. There is one single spot, thought, that I is locking it and won't let me separate more than about 1mm there. Pics below:






As you can see, I did not remove the clutch basket/assembly. Do I have to? Or do you think there is some other internal part that is preventing me from fully separating the cases?

All help and advise will be greatly appreciated.

- Ofir
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post #2 of 4 (permalink) Old 05-24-2019, 07:34 PM
You should listen to me. No, seriously, listen to me.
 
Join Date: Oct 2008
Location: Santa Barbara
Motorcycle: Blue 2006 GSX-R1000
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Re: Splitting cases

The halves are aligned by three pins. Perhaps things are sticking at one of them.

But I wonder if you know what you're doing. The halves are a matched set that splits along the crankshaft bearings, possibly the most critical alignment on the engine. That's why they're not sold separately. IMO, replacing one half sounds like you're playing with fire unless you're a hell of a machinist.
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post #3 of 4 (permalink) Old 05-24-2019, 07:39 PM Thread Starter
Squid
 
Join Date: May 2019
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Re: Splitting cases

Never mind, it looks like the shift shaft (attached to the upper case) is holding the gearshift cam plate (attached to the lower case). I guess I do need to remove the clutch basket after all.
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post #4 of 4 (permalink) Old 05-24-2019, 11:03 PM Thread Starter
Squid
 
Join Date: May 2019
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Re: Splitting cases

Quote:
Originally Posted by BillV View Post
The halves are aligned by three pins. Perhaps things are sticking at one of them.

But I wonder if you know what you're doing. The halves are a matched set that splits along the crankshaft bearings, possibly the most critical alignment on the engine. That's why they're not sold separately. IMO, replacing one half sounds like you're playing with fire unless you're a hell of a machinist.
Thanks for the input. I have two full sets of matching cases so I can use one of them if needed.
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