Topic: Cases Won't Split

[Ellz10]

I'm so close to just taking this motor and tossing it over the bridge behind my house. I've literally had it with this effing thing. The cases wont open no matter what I do. All bolts are out, I've looked it over more than a dozen times. Even though I didn't need to, I took the flywheel off. All the gear shift lever stuff is off, countershaft bearing holder is off, anything you can think of that needs to be off, is off. I spent several minutes with the torch along the case split line and still nothing. Tried a mallet against PVC pipe touching the oil filter bolt hole, nothing. Tried taking sharp blades along the case split line, nothing. I am so fed up.

What in the f*@! am I missing?!?!

[Shtonecb500]

Brother, put it all down and turn to something else for now and just take a breath. I've seen guys work for 4-5-6 days trying to split cases before.

I've been close to kicking my bike over out of frustration, pouring gas on it and lighting it on fire, getting it rolling and letting it go into traffic or a side of a brick building.....none of it would have been worth it....so dont throw it over ur bridge.

You'll get this bad boy.

[AlekStooge]

Yes, please walk away for a bit.

One time I forgot to pull the primary shaft. I had an inch gap all the way around and was so frustrated me and another person couldn't figure out that it was the primary chain holding the two cases together.

Take a break for the day. Tomorrow look at the illustrations on CMSNL and go back to it. Find someone here with the same bike as yours.

[BenelliSEI]

Take a break…… I had the same issue getting the top end away from the cases on my sand cast project. Took me a few days and in the end, I built a tool to help.

A few years ago(?), “Lash” had the same problem and built a puller/splitter tool that worked beautifully. Maybe search through his posts? Anyone else remember that?

[PeWe]

There are some long M6 screws to be forgotten.
Inside starter motor cover, lower case between clutch and ignition.
On other side too.

I have been close to use too much force  but stopped in time finding the forgotten long M6 before ruin the thread in case. Maybe 75mm - 100mm long.

[Ellz10]

Thank you to all of you. I rarely allow myself to get so heated to the point of wanting to break something.

I read your replies last night, and while I didn't say anything in response, I listened and took a break and called it a night.

Fast-forward to this afternoon and I read Pete's post and I swear to God I was so close to throwing MYSELF off that damn bridge. I cannot believe I forgot about that bolt under the starter motor cover!!

Once that was out, she opened right up.

Thank you all.

[Don R]

 Sorry I'm late to the throwing #$%* off the bridge party but my motto is, "there's always one more bolt".

[Ellz10]

Sorry I'm late to the throwing #$%* off the bridge party but my motto is, "there's always one more bolt".

Hah, I should make a plaque for that and mount it on the wall!

[BenelliSEI]

Well done. A buddy of mine always says; “If this was simple, anyone could do it!”……

[BenelliSEI]

There are some long M6 screws to be forgotten.
Inside starter motor cover, lower case between clutch and ignition.
On other side too.

I have been close to use too much force  but stopped in time finding the forgotten long M6 before ruin the thread in case. Maybe 75mm - 100mm long.

Good catch PeWe!

[MauiK3]

This is the best forum!
Get Hondaman’s book, I know I always say this but it’s true.

[PeWe]

There are some long M6 screws to be forgotten.
Inside starter motor cover, lower case between clutch and ignition.
On other side too.

I have been close to use too much force  but stopped in time finding the forgotten long M6 before ruin the thread in case. Maybe 75mm - 100mm long.

Good catch PeWe!

Been there!

[Floshenbarnical]

The number of times I have said out loud "I'm going to roll this f****** thing into the f****** river" while working on this bike is greater than the number of times I have had hot dinners. I feel your pain brother.

That's usually the point at which I call it a day, and come back to it the next day with fresh determination.

[MauiK3]

I have learned not to start things or continue with a frustrating thing when....
I'm tired
I'm hungry
Mad
Too distracted
It's late in the day

Come back with a clearer head.

[PeWe]

I usually take photos during assembly.  So easy with phones of today.

For my 2nd thoughts afterwards, "did I really add that or those in correct way?"

I have been forced to take things apart again to check when I had mounted all in a kind of auto mode.

Do not store extra parts on the bench where working. I found a "lock ring" for final shaft inside oil seal on my bench after the engine was put together.

I had photos where I saw the ring in place before closing cases.