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Splitting Lower Cases

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  • Splitting Lower Cases

    I am trying to split the lower cases on a '94 750 Katana. We have a service manual for the bike and removed all bolts and nut (even 2 that were hiding on the front of the engine), but we cannot get the cases to split.

    We have gone around and tapped with a rubber mallet (per the manual) and shimmed the cases apart. But cannot remove it whatsoever.

    I saw a plate around crankshaft where the oil pressure sender unit is and removed the screws from that- but that did not work either.

    Does the clutch have to come out before splitting the cases? We did not find any mention of that in the service manual.

    Does anybody have any other tips?

    TIA
    Mine - 2005 Suzuki SV650S
    Hers - 2006 Kawasaki Ninja 650R

  • #2
    PM Special K. He can help you out with this.
    www.mopowersports.com

    Comment


    • #3
      Cool, thank you.
      Mine - 2005 Suzuki SV650S
      Hers - 2006 Kawasaki Ninja 650R

      Comment


      • #4
        If it has alot of miles on it, it will take some work to get them apart. I can't see what you are working with to tell you if there is a bolt still in the case or not. Look the case over very thoroughly and make sure you have them all out.
        TDA Racing/Motorsports
        1982 Honda CB750 Nighthawk, 1978 Suzuki GS750 1986 Honda CBR600 Hurricane; 1978 Suzuki GS1100E; 1982 Honda CB750F supersport, 1993 Suzuki Katana GSX750FP. 1981 Suzuki GS1100E (heavily Modified) http://katriders.com/vb/showthread.php?t=94258
        Who knows what is next?
        Builder of the KOTM Mreedohio september winning chrome project. I consider this one to be one of my bikes also!
        Please look at this build! http://katriders.com/vb/showthread.php?t=91192

        Comment


        • #5
          That's what I was thinking. It's the original engine, so it's 11-years-old; however, it only has 9,500 or so miles on it.

          The seal has been split. We spent several hours getting that far.

          I will post a page with some pics here in a few...
          Mine - 2005 Suzuki SV650S
          Hers - 2006 Kawasaki Ninja 650R

          Comment


          • #6
            OK, here is a little page a through together real quick just to show pics of the work completed this far.

            http://people.umw.edu/~timothyg/katengine.htm
            Mine - 2005 Suzuki SV650S
            Hers - 2006 Kawasaki Ninja 650R

            Comment


            • #7
              ask Special K but I think there is a couple of bolts on the inner case. The top end might have to come off but ask K first.
              TDA Racing/Motorsports
              1982 Honda CB750 Nighthawk, 1978 Suzuki GS750 1986 Honda CBR600 Hurricane; 1978 Suzuki GS1100E; 1982 Honda CB750F supersport, 1993 Suzuki Katana GSX750FP. 1981 Suzuki GS1100E (heavily Modified) http://katriders.com/vb/showthread.php?t=94258
              Who knows what is next?
              Builder of the KOTM Mreedohio september winning chrome project. I consider this one to be one of my bikes also!
              Please look at this build! http://katriders.com/vb/showthread.php?t=91192

              Comment


              • #8
                Yeah, I PM'd him, so hopefully you can provide some insight. My understanding with this particular motor is that only the lower case had to come off. As opposed to other engines that required taking the head off.
                Mine - 2005 Suzuki SV650S
                Hers - 2006 Kawasaki Ninja 650R

                Comment


                • #9
                  look at this schymatic and see if it helps you at all
                  http://bikebandit.com/partsbandit/sh...id~1031384.asp
                  TDA Racing/Motorsports
                  1982 Honda CB750 Nighthawk, 1978 Suzuki GS750 1986 Honda CBR600 Hurricane; 1978 Suzuki GS1100E; 1982 Honda CB750F supersport, 1993 Suzuki Katana GSX750FP. 1981 Suzuki GS1100E (heavily Modified) http://katriders.com/vb/showthread.php?t=94258
                  Who knows what is next?
                  Builder of the KOTM Mreedohio september winning chrome project. I consider this one to be one of my bikes also!
                  Please look at this build! http://katriders.com/vb/showthread.php?t=91192

                  Comment


                  • #10
                    Originally posted by THAZKAT
                    look at this schymatic and see if it helps you at all
                    http://bikebandit.com/partsbandit/sh...id~1031384.asp
                    Cool, thank you. I found one nut that may not have gotten removed- #25 that goes on stud #23. Wish I could leave work right now and look at it .
                    Mine - 2005 Suzuki SV650S
                    Hers - 2006 Kawasaki Ninja 650R

                    Comment


                    • #11
                      No prob. bro, thank you for getting back to me. Did you here from Keith yet?
                      TDA Racing/Motorsports
                      1982 Honda CB750 Nighthawk, 1978 Suzuki GS750 1986 Honda CBR600 Hurricane; 1978 Suzuki GS1100E; 1982 Honda CB750F supersport, 1993 Suzuki Katana GSX750FP. 1981 Suzuki GS1100E (heavily Modified) http://katriders.com/vb/showthread.php?t=94258
                      Who knows what is next?
                      Builder of the KOTM Mreedohio september winning chrome project. I consider this one to be one of my bikes also!
                      Please look at this build! http://katriders.com/vb/showthread.php?t=91192

                      Comment


                      • #12
                        Originally posted by THAZKAT
                        No prob. bro, thank you for getting back to me. Did you here from Keith yet?
                        Nope, nothing yet . Guess that's for the best because I don't get off from work until 9:30 tonight. Saves me from calling in sick from the second job.
                        Mine - 2005 Suzuki SV650S
                        Hers - 2006 Kawasaki Ninja 650R

                        Comment


                        • #13
                          ha ha ha
                          TDA Racing/Motorsports
                          1982 Honda CB750 Nighthawk, 1978 Suzuki GS750 1986 Honda CBR600 Hurricane; 1978 Suzuki GS1100E; 1982 Honda CB750F supersport, 1993 Suzuki Katana GSX750FP. 1981 Suzuki GS1100E (heavily Modified) http://katriders.com/vb/showthread.php?t=94258
                          Who knows what is next?
                          Builder of the KOTM Mreedohio september winning chrome project. I consider this one to be one of my bikes also!
                          Please look at this build! http://katriders.com/vb/showthread.php?t=91192

                          Comment


                          • #14
                            The topend has to come off to split the case. According to haynes and clymer manuals.
                            '92 Kat restoration/mod project

                            Comment


                            • #15
                              See, that is what I thought. I personally haven't had the cases split so I couldn't honestly say.
                              TDA Racing/Motorsports
                              1982 Honda CB750 Nighthawk, 1978 Suzuki GS750 1986 Honda CBR600 Hurricane; 1978 Suzuki GS1100E; 1982 Honda CB750F supersport, 1993 Suzuki Katana GSX750FP. 1981 Suzuki GS1100E (heavily Modified) http://katriders.com/vb/showthread.php?t=94258
                              Who knows what is next?
                              Builder of the KOTM Mreedohio september winning chrome project. I consider this one to be one of my bikes also!
                              Please look at this build! http://katriders.com/vb/showthread.php?t=91192

                              Comment

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