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Splitting the Crankcase

  #1  
Old 04-10-2017, 09:28 PM
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Default Splitting the Crankcase

So winter passed and I decided to do some maintenance on my 01 F4i. I got laid off at the end of February so I have ample free time and started with a compression test. 3 out of 4 cylinders tested in the 150 psi range and the last one 120 psi. So I popped some oil down the hole and it zoomed up to 160. From the reading I did it sounded like the piston needs a new ring or the cylinder needs to be bored.

Fast forward, I dropped the engine; removed the cylinder head; removed the clutch cover; removed the alternator cover; removed the oil pan and the throttle bodies. Now to split the crankcase so I can remove the pistons to replace the rings the service manual states I need to remove the clutch & alternator/flywheel both of which require a special tool which I don't have. But from what I can see the upper half should just split from the lower without disturbing either. Has anyone had experience in doing this? am I able to split the crankcase without removing both the clutch & alternator? Any help would be greatly appreciated.

Other details:
54,000 KM's/33,500 Miles on the bike

Photos of removed engine
 
  #2  
Old 04-21-2017, 02:51 PM
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Well since no one else replied I answered my own question by powering forward into the unknown. You have to remove the oil cooler, clutch basket and main wheel bearing chain. But the alternator and flywheel can be left alone. The clutch basket is a 30mm socket.
 
  #3  
Old 04-21-2017, 04:13 PM
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Well done mate, you're a brave man!

As they used to say on Star Trek 'To boldly go where no man has gone before'.

Let us know how your progress goes.
 
  #4  
Old 06-26-2018, 05:28 PM
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I'm in the same boat as you are. Unemployed and trying to swap a bent crankshaft. I have removed all the hardware except for the clutch cover.

When you say clutch basket, is that basically pulling the entire clutch assembly out?

What do you mean by main wheel bearing? I don't think I have removed this yet
 
  #5  
Old 06-26-2018, 08:15 PM
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Originally Posted by Pmartone View Post
I'm in the same boat as you are. Unemployed and trying to swap a bent crankshaft. I have removed all the hardware except for the clutch cover.

When you say clutch basket, is that basically pulling the entire clutch assembly out?

What do you mean by main wheel bearing? I don't think I have removed this yet
You are correct, removing the clutch basket is pretty much removing the whole clutch. And I think what I meant by wheel bearing chain was the drive chain.



Clutch basket



Drive chain

I also made a video of the rebuild, if you think it will help you can check it out here
.
 
  #6  
Old 06-26-2018, 08:27 PM
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Thank you so much. This is also my first rebuild.

So I am removing a chain, not a bearing?

How did you remove the clutch cover and how did you separate the lower half and upper half of the engine without damaging anything?
 
  #7  
Old 06-27-2018, 08:52 AM
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Originally Posted by Pmartone View Post
Thank you so much. This is also my first rebuild.

So I am removing a chain, not a bearing?

How did you remove the clutch cover and how did you separate the lower half and upper half of the engine without damaging anything?
Yes you will have to remove the chain. To remove the clutch cover you just need to remove the 10 or so bolts and pull it off. Do you have a copy of the service manual?

For seperating the lower and upper half was pretty easy. Just make sure all the bolts are removed and I believe the engine has to be upside down and it comes apart fairly easy.
 
  #8  
Old 07-07-2018, 08:38 PM
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I have the clutch basket out now. Is there a way to remove the drive chain. Also is there a way to remove the timing chain to the right of the clutch basket? I don't want to remove the Head as i am just swapping a crankshaft
 
  #9  
Old 07-12-2018, 07:00 PM
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Originally Posted by Pmartone View Post
I have the clutch basket out now. Is there a way to remove the drive chain. Also is there a way to remove the timing chain to the right of the clutch basket? I don't want to remove the Head as i am just swapping a crankshaft
Sorry I have been away. You should be able to just un-bolt one of the bolts holding both the cam chain/timing chain and the drive chain on. In the shop manual it states the cylinder head has to be removed to separate the crankcase but you can always try.
 
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