Splitting the cases

[Old Rider]

Today i have washed the cylinder and re measured the pistonring endgaps  .Then mounted the pistonrings with plenty of oil.
a pistonring compressor was used to insert the pistons into cylinders.I used lots of oil on both rings and inside the
cylinderbore.The pistons was inserted from underside because the bore is chamfered there.
I hoping that it will work to connect the pistonrods when the pistons is sticking out just enough to get the wristpin in.
it can be problems to because the lower oilring is right at the edge of cylinder and want to pop out.
Also mayby difficult to insert the wristpin circlip ..

[ZOA NOM]

You should be able to rock the piston slightly downward so the pin will go. If the ring gap isn't located right above the end of the pin, the ring should stay seated.

[Old Rider]

You should be able to rock the piston slightly downward so the pin will go. If the ring gap isn't located right above the end of the pin, the ring should stay seated.

I think it might work the ring gap  on the lower oilring is at the nr 2 position on the pic from the manual.

[Old Rider]

Yesterday i did  some more work .First  that little dowelpin i by mistake removed from transmission outputshaft bearing was put back in.It was still a tight fit and i gently tapped it back in.
Then i replaced the transmission oilseal .I used moly sulfi grease on the oilseallips not sure if that is wrong type of grease to use on a oilseal.
Then the starterchain damper was mounted The manual instructs to use non hardening loctite .I did not find that so i used green loctite on the 2 bolts and torqed them to 10NM.
The plan was to do more work but then i discovered that i have to replace that rodbolt that im waiting on before
i can continue.
Im thinking of mayby use a little rtv on the outside of the crankshaft oilseal and endplug  It looks like the po has used rtv there ??

[Old Rider]

Today i got the new rodbolts so first i replaced the one i had problems with when torqed it .Then i installed the
starterchain and camchain the starterclutch and oiljetnozzle .Then i tested that the transmission shifting works right so i dont get a surprice when
engine is back in the bike 
The manual says to lay the uppercase with cranchaft installed on top of the lower case .I think i will be easier
to put the lowercase with the transmission inside ziptied so it dont fall out when flipped.Then lay the lowercase on
top of the uppercase .I think it is easier to control because it is lighter.also when starting to torqe the first
bolts number 1 to 10 they all are on the underside of lower case and i dont have to flip the hole engine

[Troyskie]

Having never split a case I think this is great! I probably would have completely f@#ked it up about 4 times before getting help.

Great stuff mate  .

[ZOA NOM]

The instruction shown regarding which half to place onto which may have a purpose. The heavier weight of the half with the crankshaft in it will assist in sealing the halves when it is set down. Having said that, the torque sequence of the mating bolts should do the same thing. My "Porche" (Randy's spelling) motor is assembled heavy side down. Just tossing some extra stress your way.  

[racerrad8]

The instruction shown regarding which half to place onto which may have a purpose. The heavier weight of the half with the crankshaft in it will assist in sealing the halves when it is set down. Having said that, the torque sequence of the mating bolts should do the same thing. My "Porche" (Randy's spelling) motor is assembled heavy side down. Just tossing some extra stress your way.  

Oh Ricky...

you spelled it wrong again...Poorche

BTW, we have added some Poorche 911 parts to the RPM inventory. You can find them by just using 911 in the search field.

Randy - RPM

[racerrad8]

I leave the upper case with the crank on the bench like you have it.

I then hold the transmission in place with my hands from the outside and lay it onto the upper portion.

The zip tie idea you have seems like a good idea, but what supports the other end of the trans from falling out? With my hands, I can load the shafts and hold them in place as I put it over the top of the crank.

Make sure you have the two dowel pins and center case o-ring in place.

Randy - RPM

[FJ1200W]

I'm going to be reading and reading this thread for a while - great info, thank you

[Old Rider]

Yesterday evening i put the cases togheter  torqued everything up and glued together with permatex  ul black and everything was fine ...well  i tought  
later on the evening  i started thinking about when i tok the transmission out again a last time because i wanted to be sure there was a little shim /washer mayby missing at the first gear since i had  the first gear off the axle many times when checking the transmission. The little washer/shim was in place and everything was fine and then i put the trans back in again ziptied it and started to aply permatex on the mating surfaces.
Then joined the cases and i torqued everything, but  gess what i forgot to check.....?. i going down in my cellar now to check some more now wish me luck

[Old Rider]

I have now been down in my cellar and checked if the seam is gaping where the little dowelpin in the transmission outputshaft bearing  is located.That is what i forgot yesterday .When i tok the transmission out for a last check and put it back in again
i managed to forget to see if that little .... pin was in its slot in the seamline in the case.
I cant see any signs of bad fit or gaping in the seamline.I have tested if the transmission works and turns easy
and it does.I dont know if the dowelpin is crushed totally into the alu on the case or if i have got very lucky
and the dowelpin was in the right position but what are the odds of that ??

[Old Rider]

Today i have been down i cellar again.Since im not sure what happened with the little dowelpin in the big transmission output shaft bearing i decided that i had to split the cases again to check that it was not crushed into the soft case aluminium and mayby done some damage to the bearing.
When i reopened cases i cold see that the job was not needed since the dowelpin was in the right place  !
so then i started the job cleaning the gasket surfaces again. Then i joined the cases again and did check  that the dowelpins and the orange oring was in right place before joining  
Then i had some more fun because when i was torquing the bolts and had came to bolt number 21 it decided to just snap off deep in the other case with a little bang   no warning signs first just snapped off and the torque wrench was at only 10NM non of the other bolts snapped so i guess the bolt was fatigued.I would have tough that the soft tread in the aluminiumcase would had been stripped before the bolt snapped???
First was thinking what the hell i just leave the rest of the shared off bolt in there and drive without the bolt
but then i decided that i had to split the cases for the third time and get the rest of the bolt out and that it was easier to re apply the permatex ultra black rtv while it was not hardenedyet.
When  the cases was opened again i could easy unscrew the rest of the bolt with my fingers.I think my fingergrip was a little harder than usual at the moment
So then i applied more permatex and joined the cases again for the third time i hope it is the last.
i will order Bolt nr 21 tomorrow  and screw it in

[ZOA NOM]

You definitely get the award for persistence. And the writeup with pics is first class. Mods please archive!

[Pat Conlon]

Rick, you were reading my mind.