can't get cases together

[sangheraent]

hey all iv been trying to put my engine cases back together and I can't seem to get them past a certain point. it feels like its sticking somewhere but everything is lined up perfectly i wiggled aorund my gears and still nothing tried for like an hour.

is there some sort of trick to this or is it suppose to be super hard?

[morse250r]

need the honda puller to get it back together

[sangheraent]

oh theres a special tool needed to put it together?

[Rich250RRacer]

Originally posted by sangheraent
oh theres a special tool needed to put it together?

Yes there is.

http://i228.photobucket.com/albums/ee108/rich250rracer/motor%20rebuild/mot15.jpg

http://i228.photobucket.com/albums/ee108/rich250rracer/motor%20rebuild/mot16.jpg

[sangheraent]

well iv got the crank seated in the case. I just cant get the other side case on it goes about an inch and then it seems like it sits on something. I think it may be the shorter gear shaft but Im not too sure.

[All250R]

Originally posted by sangheraent
well iv got the crank seated in the case. I just cant get the other side case on it goes about an inch and then it seems like it sits on something. I think it may be the shorter gear shaft but Im not too sure.
If you have an OEM crank bottom, you don't need a tool to assemble the cases. So if you do use a tool, you're potentially going to break something. The OEM crank is a slip fit into the right main bearing - it's secured with a bolt, not a tolerance fit. You could view the OEM cranks as the "correct" part for this engine from that perspective, but that's a different point.

The cases slip together pretty easily usually. Check your dowel alignment, but often times it's the trans shafts having a tight fit into the bearings is where you might have to gently massage them into place - but don't ever force them with a tool. If the trans shafts being a little snug in the bearings is not your problem you assembled something else incorrectly, or you're not using an OEM crank bottom, and at that point you'll have to take your pick which one is the hold up.

[morse250r]

ive had oem cases and cracks not go in with out the tool

[86 Quad R]

Originally posted by morse250r
ive had oem cases and cracks not go in with out the tool

every one that i've assembled(oem crank or other) has been without a tool aswell. if you can determine if its something in the tranny area, you may opt to lay the engine on its side to help line things up a bit better. if you are getting a tighter than normal fit of the crank to bearing, you can slightly heat up the inner race of the crank bearing with a propane torch. this works very well. :cool:

[Langbolt]

I've always left the Crank in the FREEZER for a few days and then WARMED the bearing with a heatgun......Drops right in!

Where do you get this TOOL from ?

Is it a HONDA specialty tool

:devil:

[312R1]

Originally posted by Langbolt
Where do you get this TOOL from ?

Is it a HONDA specialty tool

:devil:


I bought mine from Honda, I'm not sure if you can get it elsewhere.

-Steve

[Rich250RRacer]

Originally posted by Langbolt
I've always left the Crank in the FREEZER for a few days and then WARMED the bearing with a heatgun......Drops right in!

Where do you get this TOOL from ?

Is it a HONDA specialty tool

:devil:

It's Honda only and the part numbers are in the OEM service manual. It's sold in three pieces.

[Langbolt]

Thanks for the info..... :D

Is that the one on page 8-8 ?

Driveshaft dis/Assembly tool (B) 07964-MB00200

Assembly bolt 07965-1660200

Where's the third part ? :(

[All250R]

Originally posted by Langbolt
Thanks for the info..... :D

Is that the one on page 8-8 ?

Driveshaft dis/Assembly tool (B) 07964-MB00200

Assembly bolt 07965-1660200

Where's the third part ? :(
Everyone is trying to help, and that's great. You need to understand that you do not need a case assembly tool if you're installing with an OEM crank. There is a crank assembly tool to install the crank, but not for the case halves themselves. If you can state what type of crank you're installing that would start to make your situation a little more clear. If not, you're not getting advice for your specific problem yet.

[sangheraent]

im putting together a stock crank with stock cases. I got my crank in with no issues at all but my cases are definetly hitting something. I give it a bunch of light taps with the mallet and still no movement i got the motor on its side too. I agree you dont need a tool to put it together mines just being a *****.

[All250R]

Originally posted by sangheraent
im putting together a stock crank with stock cases. I got my crank in with no issues at all but my cases are definetly hitting something. I give it a bunch of light taps with the mallet and still no movement i got the motor on its side too. I agree you dont need a tool to put it together mines just being a *****.
Find out where it's binding and that will solve your problem. You may want to take your trans shafts and see if they'll slide into each case independently to see if that's your issue - just as a place to start.

[Langbolt]

Did the Mainshaft and Outpu shaft go into the Left case ok ?

If there's a gear that's not quite located right it'll pose an issue...

I'm thinking maybe when you're attaching the Right side that it's hitting the Shift drum ???

Or is that passing through the bearing fine ?

You can check this by removing the shift drum and try insert it into the Bearing in the Right case.....if it doesn't slip in all the way ...there's your problem.

Are your Shift fork Pegs in all the way ?

Pull them out and make sure the holes aren't full of OIL.....that'll stop them from going all the way down.

Keep us posted

:devil: