Splitting Lower Cases

[SVTim]

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

[HS2020]

PM Special K. He can help you out with this.

[SVTim]

Cool, thank you.

[ThAzKat]

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.

[SVTim]

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...

[SVTim]

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

[ThAzKat]

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.

[SVTim]

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.

[ThAzKat]

look at this schymatic and see if it helps you at all

http://bikebandit.com/partsbandit/showschematic~dept_id~1031384.asp

[SVTim]

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 .

[ThAzKat]

No prob. bro, thank you for getting back to me. Did you here from Keith yet?

[SVTim]

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.

[ThAzKat]

ha ha ha

[floxera]

The topend has to come off to split the case. According to haynes and clymer manuals.

[ThAzKat]

See, that is what I thought. I personally haven't had the cases split so I couldn't honestly say.