Question about 2000 Harley Davidson XL Sportster 883

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Splitting crank cases - 2000 Harley Davidson XL Sportster 883

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Hi Phillip, it's too bad you can't find the very first and best tool you ever bought for your Harley Davidson. Despair not, for a mere $6.50 you may be able to download another one from the website below and good luck. Harley Davidson Manuals Mark Workshop

Posted on Jun 09, 2015

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1 Answer

Do i need to remove engine studs on 1989 GSXR 1100 to split the crank case?


Usully, studs are simply bolts that have removable nuts on them. You should not have to remove the studs to split the case.

Dec 18, 2012 | Motorcycles

1 Answer

1989 GSXR 1100 splitting the crank case?


answered my own question. No you do not have to remove engine studs to split the case. You do have to make sure that all of the case bolts are removed, even if they arent in the manual.

Dec 18, 2012 | Suzuki Motorcycles

1 Answer

Do you have to disassemble the transmission to split the crank case?


Yes you need to split cases to check the transmission and once you've spitted the cases, it is best to renew the bearings cause is quite a trouble to do that again soon if any of the bearing are about to go bad.

Feb 07, 2012 | 2004 Suzuki DR-Z 125

1 Answer

I have a Honda cr 125 2002 the crank locked up so I split the cases on it is it critical the the tranny gear be lined up as when they where before the cases was split (the gears or in correct order and...


It only needs to be in neutral. Nothing else to line up. I'd be more concerned as to why the crank locked up, ie seized bearings broken gear, seize piston etc. Have you already identified the problem?

Aug 11, 2010 | 2002 Honda CR 125 R

1 Answer

How too replace connecting rod on a ttr 125l. I have a 2001 ttr 125 with a seized conn big bearing. and I would like to know the proper way of splitting the crank too replace it


The top end comes off then the left and right side covers, flywheel, clutch and shift shaft. Now a case splitter is used to split the center case halves. To replace the bearing you will need a hydraulic press to disassemble and reassemble the crank halves. If the bearing is seized you should replace the bearing, crank pin and the connecting rod. The crank must be realigned using twin dial gages. Personally, I suggest a new crank assembly be purchased from www.babbittsonline.com ( $241 ). I would replace the crank end bearings at the same time and also the sprocket shaft outer bearing and seal. Please rate my answer.

Jan 03, 2010 | 2002 Yamaha TT-R 125 L

1 Answer

My right hand crank case is split


get it welded with a tig aluminum welder

Dec 31, 2009 | 2004 Husqvarna TE 510

1 Answer

How to remove a crank on yz 125 after engine casing is split?


When you split the case (depending on how you split it) the crank will stay in the left case half or the right case half. Whichever doesn't matter. Just take a rubber mallet and knock it out of the half it is in. Now would be a good time to replace the outer bearing and seal behind the front sprocket. Also replace the shift shaft seal.

By the way, this may be helpful >
Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part and/or the notation "Not Available" is in the description, the part is not in stock. www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx

Could you take a moment and rate my answer? Thanks!

Sep 23, 2009 | 2003 Yamaha YZ 125

1 Answer

Having trouble getting the gears to select down


Since the shifting was okay prior to splitting the cas, chances are one or both of the positioning pins fell out. If this happened, the cases are not lined up correctly.

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Aug 01, 2009 | Suzuki RM 125 Motorcycles

1 Answer

How do I take off the Magneto off a 2003 Yamaha 125


If replacing the piston pin bearing no splitting is needed. If replacing the crank pin bearing splitting is needed. You knew that I am sure but I had to clarify. The flywheel is held in place with one washer and a nut on the end of the crank. Timing is accomplished with a woodruff key on the shaft. Using a flywheel puller tool is the proper method. It is a simple and low cost tool and it sounds like you have enough knowledge of engines to need one now and in the future. In a worst case scenario, use a mallet, striking the flywheel on four points around the perimeter of the wheel and in an "outward" direction. With some luck the flywheel will pop loose.

When you are purchasing the flywheel puller, buy a case splitter also. Also reasonably low cost, it makes the splitting clean and easy. I strongly suggest you install new crank bearings and seals. Whatever caused the crank pin bearing to go bad did not do the crank main bearings any good either. I would hate to see you have to split the case again eight weeks from now.

How are you planning to separate the crank halves, re-assembly and truing of the crank? The dealer should do this part. I can't find a free repair manual on the web but the next best is a parts diagram. Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock.
www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx

Top rating on this solution? Thanks!


May 24, 2009 | 2003 Yamaha YZ 125

1 Answer

Suzuki 125rm manual


Find a manual by Googling " Motorcycle service manuals "
or go to www.repairmanuals.com

Installing new crank bearings is not a simple task. you will need a 3/8" impact driver, flywheel puller, case splitter and torque wrench. The top end comes off then the side cases, flywheel, flywheel electrics, clutch, shifter shaft, Crank drive gear and output shaft sprocket.

Split the case leaving the gears on the shafts and the shift drum and forks in place but out of the gearbox. Remove the crank and then remove the bearings from the crank or from the center casings depending on where they decide to stay when the case splits. Remove the crank seals from each center case half. Install new seals then install new bearings into the center casings.

Now just put everything back together.
By the way, now would be a good time to stick in a new output shaft (sprocket) bearing and seal. Be sure the OHC is timed correctly when installing the cam chain. Bad timing = bent valves.

Please rate this answer. Best wishes amcampailla

Mar 14, 2009 | 2003 Suzuki RM 125

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