Splitting the crankcase

[justinsch2444]

So I'm splitting the crankcases tmrw (at least I intend to ) and I've been trying to find legit step by step instructions, so I don't cause any more problems and ride before the snow flies. This is what I've found thus far, with a few steps in question:

drain case oil, removing drain plug adjacent bolt
remove engine from frame, easiest way by laying on its side with a friends help
remove all "S" suzuki bolts on top and on bottom of crankcase
remove clutch basket and retaining clip?
remove retaining clips behind alternator and front sprocket?
pry cases apart?

I've seen mixed comments if you need a special tool or not for removing the clutch basket. Also, whats the best sealant to use after reassembling the cases?

Can the engine be upside down when removing the lower case? I honestly have no clue how things will drop out, I've never split and engine case before.

I'm replacing the tach drive and was told after splitting the cases I should be able to just replace. I'm also going to do the JB weld/tin can gearbox mod while I'm in there. ANY suggestions or tips welcome, as I am dedicating my entire day to this and hope I can put her all back together and crack a beer.

[Suzukidave]

Here is a shop manual http://www.oldjapanesebikes.com/mraxl_G ... index.html" onclick="window.open(this.href);return false;

[mike1161]

Just some other tips, it's good to get the clutch nut loosened before you splith the cases, there are some special tools for holding the basket while you do this, another easier trick it to use an impact wrench, it breaks the nut free in a second (or if you don't have an impact wrench, take the motor to your local shop, they will probably do it for free, since it really does just take a second). Also make sure you really did loosen all the case bolts (I've missed some before ). When all the bolts are out, some light tapping with a piece of wood, and they will come right apart; don't pry anything with a screwdriver, etc...you don't want to damage those case mating surfaces. For the sealant, I've had great luck with ThreeBond Liquid Gasket 1194. Its's a semi-drying compound & works great, put on a nice even bead on all case mating surfaces.

[justinsch2444]

Thanks for the impact and wood tip and wow! that shop manual is a lot better than the pdf I had. I am actually looking forward to this