250es Case splitting question

[jeremyb74]

85 big red. I'm splitting the cases mainly just to retrieve a washer I dropped in messing with the kick starter inside the right half. Does the alternater parts have to come off? The manual says yes, but looking at where left case half bolts are, and since I'm not taking the crank out, I don't see why anything but the starter and left cover (to get to case half bolts) would have to come off the left side. Not trying to be lazy, just don't have specialty tools and stuff... the clutches were bad enough without a holder lol

[Tecate Karl]

Every time a split an sx motor same as the es I pull the flywheel you need to because in case the crank is stuck to one side you don't want it pulling against the case and trashing your cases.

[Slingblade]

Try every way possible to get that that washer out before you split those cases. Shake it out of the drain plug, the oil return hole, something. How big is the washer? You really don't know what your getting into. If you read the rest of the manual it will probably say that behind the electrical parts is where the case splitter should be used. You don't have to buy an expensive splitter, you can use a puller from the parts store, but I would reccomend you use one and not ruin the cases with a hammer and screwdriver. Some people think just because they can the remove the side covers, splitting the cases is no big deal. It is.

[jeremyb74]

Try every way possible to get that that washer out before you split those cases. Shake it out of the drain plug, the oil return hole, something. How big is the washer? You really don't know what your getting into. If you read the rest of the manual it will probably say that behind the electrical parts is where the case splitter should be used. You don't have to buy an expensive splitter, you can use a puller from the parts store, but I would reccomend you use one and not ruin the cases with a hammer and screwdriver. Some people think just because they can the remove the side covers, splitting the cases is no big deal. It is.

Thanks guys. I have the motor out, when I get the top end off I'll try and shake the washer out. I can't see it, but I know it's in there. It's about an inch in diameter, it is the one on the backside of the kickstart shaft. Actually the manual doesn't even mention a case splitter. I'm not a mechanic, but I'm not totally new to this stuff either. As a former motocrosser, I've always done my own work, plenty of top ends, valves and stuff. Splitting cases is about the only thing I've never done. And I'm not taking it lightly, I'm kinda nervous about it, but I have to learn some time.

[250rmanfmf]

I second not spliting cases, It sucks to do, if you do split them the stator and flywheel have to come off. also dont take out your drive unit either as a whole lot more washers will be going into your tranny.

[Slingblade]

Jeremy, don't get me wrong. I believe 100% you can do it if you have to, If you get the top end off and the crank has play in it, you may HAVE to. Just trying to save you some work and headaches. But you're right, that is the only way to learn, so if you have to..... Go at it Bro., We'll help you get 'er back together.

[jeremyb74]

Jeremy, don't get me wrong. I believe 100% you can do it if you have to, If you get the top end off and the crank has play in it, you may HAVE to. Just trying to save you some work and headaches. But you're right, that is the only way to learn, so if you have to..... Go at it Bro., We'll help you get 'er back together.

Oh trust me, I won't do it if I don't have too. The missing washer is so light and thin that I'm afraid it will be stuck against the case in oil or something. I'm not confident that I can shake it out, but I'll sure as hell try! The upside is, while I was planning on replacing the head gasket, I bought a complete gasket kit off ebay... so I have replacement for whatever seals and gaskets I need.

[Woodsrider]

Did you try fishing with a magnet type thing with a flexible shaft....just shove it down the hole that is exposed when the kicker assembly is removed. Try tossing the engine around a bit to move the washer into a better location if you don't have any luck the first time. This has worked for me in the past...but I didn't move anything after it fell in the hole, and it was easy to get.

[Thorpe]

I even tip the motor upside down and blow compressed air in it... (messy, but not wanting to split cases...) What was difficult about the clutch? It took me about an hour to do mine....

[Dirtcrasher]

I had a post years ago about retrieving both the thrust washer behind 1st gear when people pull the out put shaft and when a washer falls off from behind the kicker.

Remove the kicker, fill the engine with gas or diesel until it's all flushed out. Then you can use a light and a magnet to get it out. I've done it several times for several people. Your top end didn't even have to come off, just the clutch cover.......

If you must split the cases, thumper cases usually tap apart with a plastic hammer, I rarely need a puller

[jeremyb74]

I even tip the motor upside down and blow compressed air in it... (messy, but not wanting to split cases...) What was difficult about the clutch? It took me about an hour to do mine....

I'm a motocrosser, I've never messed with centrifugal clutches. I didn't have a holder for it, so I had to take it to my dads to use and air impact to get the nuts off both clutches. I've done plenty of clutch jobs on race bikes and this would have been just as easy as them if I would have had the proper tools.

[jeremyb74]

I had a post years ago about retrieving both the thrust washer behind 1st gear when people pull the out put shaft and when a washer falls off from behind the kicker.

Remove the kicker, fill the engine with gas or diesel until it's all flushed out. Then you can use a light and a magnet to get it out. I've done it several times for several people. Your top end didn't even have to come off, just the clutch cover.......

If you must split the cases, thumper cases usually tap apart with a plastic hammer, I rarely need a puller

Thanks, I'll try that! I'll be pulling the top end anyway because it has a leaky head gasket and it is a used and abused machine (before I got it) and I want to check out the cylinder

[Dirtcrasher]

I should have said, fill it with gas or diesel, shake it around and then once everything is washed of oil, drain it out and take your cover off.

You probably understood me anyhow, the idea is just to get it loose in there; Oil tends to stick things together.

Put grease on that washer when you reinstall to prevent it from falling out........

[jeremyb74]

Thanks for the help guys.... That was a great idea... pulled top end off (had to drill out one of the hex bolts in the head). Dumped about 2 gallons of kerosene through the motor via the top end. Carried it back into the garage and started looking around with a light and spotted the washer. Grabbed my longest screw driver and rubbed it on a magnet to magnetize it and shoved it in the one of the transfer holes in the right half and after a couple tries I got it thru the hole enough to grab it with some small needle nose pliers. So I'm ready to start putting things back together (after a piston and bore job since bore looked a little rough for my tastes).

Now time to tear into the rear to see what is stripped out, which is what started this whole project!

Thanks again everyone!