Suzuki 2 Strokes

Can someone please offer some help.I have been trying for two weeks to get the Cc on my t500 apart. The best i can get is 1/4" apart at front. I have tried everything I can think of. All bolts are out and the little side plate the connects the two halves. It soaked in a bath of diesel and atf for aver a week.I have suspended it off the bench and used a timing wheel pulley and nylon block to put pressure on the crankshaft where the cylinders came off. Short of c4 I cant think of anything else to try.

Are you sure all of the case bolts are out, T500 engines are really simple, so you have missed something.

I have gone over the bolts a half dozen times to be sure. all the bottom ones are out and about three more from the top.

Dam I think i found the issue. I looked closer at the exploded drawing of the transmission and see there is a plate behind the sprocket. That side of my engine had about an inch of grease on it and even though a lot came off during its bath there is still quite a bit right behind the sprocket so I could not see it.

Doh! Easy mistake to make. You won't be the first to have done it I am sure.

Ya i chuckled about it.Then I realized i had also missed a bolt right next to the oil pump. Should have looked at diagrams closer I guess.

The cases started coming aprt as soon as those to issues where addressed. They are now about 1/2" apart all way round but they are still hung up somewhere.
The cases were assembled with no sort of gasket of any kind. I then noticed a big chunk broken out of the outer race of the clutch shaft bearing and I stopped chuckling

Wow what a frustrating task. The cases are so close to coming apart but will not let go. It seems to be the area dead center of the crankshaft both top and bottom.

I had a similar problem getting the case apart on my gt380. It turned out to be that the oil seals had welded themselves to the metal with age. I solved the problem buy using a rubber mallet whilst suspending the cases by the top half only. The weight of the crankshaft and geartrain, combined with my sharp tapping of the mallet was enough to make it let go.
I must point out that I did this with the lower half only about 1.5 inches above the work bench. NOT 3ft above the ground (that would be a sure fire way to damage the casings).
And I didn't swing the mallet like a sledge hammer.