I am part of a formula SAE team (we build small race cars) and we are using a 2007 600rr engine. We were able to remove all pistons without splitting the case, however, we aren't sure if we should split the case in order to properly torque the new pistons in. We have the time and ability to do this but aren't sure if it would be worth the time. All suggestions are welcome.

 

I would think that if you can properly torque the connecting rod bolts without having to split the case, then I don't think there would be a problem. If you can't, then I'd split the case. If you're installing high compression pistons, how confident are you in the main journal bearing oil clearances? Is that not worth taking the time? Just a thought.

 

I hadn't thought about the journal bearings, the problem is that the extension bar rubs on the inside of the case making it difficult to get a good grip on. I will consult the team and get their thoughts.

 

Just based on that statement, I'd be splitting the case.

 

I guess you've unbolted the rods thru the sump cover to change the pistons, but presumably you've put the original rods back in, same way round, same cylinder. I would expect that since you could get a socket on the cap bolts, with a universal joint or one of those extension bars with a rounded end, to unbolt them, you can torque them back up the same way. If the socket won't stay on then you've answered your own question.
Nothing you've done should affect clearances at the crankshaft so, if the engine was good before, it'll be good now.. You are using new bolts aren't you?

Out of curiosity, why high-compression pistons rather than a head skim? In fact, why high-compression pistons at all, it's pretty high to start with? There are simpler/cheaper tuning options.

 

Due to the restrictor FASE requires there is less air going into the engine. This wasn't my choice but decided by the powertrain team.