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I am in the process of splitting my cases (FINALLY) but I am having trouble with the front dowel pin. It must be rusted in there because it is causing the front of the cases to bind. I am soaking it with PBblaster overnight and will try some more tomorrow. It is about 1/8" apart now but doesn't want to go any further. The back half of the cases are ready to come apart.
Anybody ever have this problem?
Any ideas to help get the cases apart?

Hit it with a blowtorch.

Soak er down with some AeroKroil. If that wont work try a piece of wood.

Got it apart!!!!
Thanks guys!
Now another ?
Does the OEM gasket kit come with oil seals?

Negative, you need a seal kit for those...

You can get aftermarket ones really cheap......

Work just like OEM.....














................ ya , right!!!!!!!!

Is there a OEM seal kit?

sabreguy wrote:Is there a OEM seal kit?

If there is, Service Honda can get them for you...

DO NOT skimp on any gaskets, seals, or other internals...... OEM is the only way to fly.

Yup, ask me and Danny how we know...

OH trust me I was definitely going OEM! I was just wondering if anybody has found an oil seal kit because I haven't.

Also I have a question about the bearings now.
What are some tell tell signs that a bearing needs to be replaced?
I can check all but the right side crank bearing, because the crank is still in the bearing. The left side crank bearing spins very easy but looks like it has gotten hot. The only bearing that doesn't sound or feel good is the right side most forward transmission bearing. It has some drag and you can actually hear it.
Any suggestions?

sabreguy wrote:Also I have a question about the bearings now.

If the cases are split... all of them!

Yup, they are not that expensive, and if the cases are already split and you are gonna spend boo koo on OEM stuff do it right and replace all the bearings and anything else that is funky. Or you WILL regret it later!!

Most of the bearings see similar loads, if one is bad, the rest arnt far off...

And the tranny ones all run in the same trash filled oil...

Change it often!

Agreed, better to use cheap oil and change it often (to remove contaminents such as clutch friction material) then to use expensive stuff and not change it often.

I personally use expensive stuff AND change it often...

OK OK I hear you!
I am pretty good about changing oils and such. But I don't know what the previous owner had done.
I am hoping to get the jug and crank down to GSS and have him look at them. I will no longer have a stop sign shaped cylinder.
Hopefully it will look like Rob's!
Also while it is down I am going to change fork oil and both front steering and rear suspension bearings.
So I will have more Q's on those to.

sabreguy wrote:OK OK I hear you!
I will no longer have a stop sign shaped cylinder.

This is more important than you know.....

Good Job Rick!

M.F.D.B. wrote:Yup, ask me and Danny how we know...

Yeah...stupid K&S, atleast I used honda seals, replacing gaskets isn't TOO much work!

Just order the gasket kit, all new bearings and oil seals from Service Honda yesterday. The jug and crank are going to GSS on Friday. So hopefully I will be putting this thing back together by the first of July.

Here is proof that I split the cases



In this pic how on earth can I remove those two screws?
They are very tight and the screwdrivers wants to walk out and strip the head.
Do you think I can use an impact screwdriver without damaging the case?

Impact screwdriver is the man for the job.

Harbor Freight Tools

$5

Thats a good shot showing how thin the gasket surface is that seperates the crankcase from the tranny.

Be real careful when you reassemble.... Maybe a smear or two of Yamabond to hold things in position.

Or use a center punch and puncha series of dings so that it grips the gasket better. This also works well for the base gasket...

The last pic at the top of the page is definately the coolest dude ive ever met...