2003 Suzuki RM 125 Logo
Posted on Apr 13, 2011
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I am having trouble trying to split my engine case. I'm am trying to split the magneto side, I have all bolts out that I can see but still it won't come off, is there something inside the other side of the case holding it?

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tombones

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  • Master 3,567 Answers
  • Posted on Apr 13, 2011
tombones
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Joined: Mar 11, 2009
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I don't know what has not been removed so pardon me if I suggest something already removed. Remove the cylinder, intake manifold, magneto, stator, sprocket and shift lever. A case splitter is highly recommended. They don't cost that much and it makes for a clean separation. The two positioning guides will tend to hamper separation as will the crankshaft and output shaft as they slide through the bearings. That's another reason for a case splitter. Now would be a good time for new crank and output shaft bearings and seals and a new shift shaft seal. I assume the reason for the teardown is either a bent shift fork or broken gear teeth. If replacing a gear with a broken tooth or two, also replace any gears the broken gear meshes with. If you don't, you will get to do the gear repair a second time very soon after the first ride. Whatever pressure broke the teeth on one gear was also present on the meshing gear. It may look good, but it isn't. Please take a moment to rate my answer. Thanks.
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Hi i would like to know why do i only have fire on one side of my 23 hp kawasaki motor?

Assuming that you have checked the spark plug and confirmed that it has not completely failed, the most common reason is the magneto on that side has failed. (There is a separate magneto for each cylinder).

To replace a magneto, you'll need to look up which part is used on your particular engine. (You will need the brand (Briggs, etc.) and the complete engine model and type numbers from the id tag on the engine).

Then go to an intrernet parts seller and look up your part number. One place you can start at is at PartsTree
http://www.partstree.com/parts/
Once there, click on the engine icon for your engine and drill down until you find the correct magneto part number.

Replacing the magneto is simple, removing the top engine sheet metal cover involves removing a few bolts, and both magnetos are then readily available.

When installing the new magneto, you first screw it down at the furthest point away from the flywheel. Then rotate the flywheel so that the magnet is aligned with the new magneto.

As part of the new magneto, you will get a thin sheet of cardboard that you hold against the flywheel magnet and loosen the new magneto, allowing it to be pulled again the magnet (with the special cardboard spacer in between).

Use care as the magnet is quite strong and the magneto will be pulled to it with a strong force.

Now firmly tighten the two screws that mount the new magneto and slowly rotate the flywheel to remove the cardboard. Replace the engine top cover and your done.
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Cant get the case to seperate on a 1997 gsxr 1100.

have you removed the clutch assy gear as there may be a plate with bolts on either side of casings ! bolts on top and bottom side ov cases out ? if all out then there are places to hit with hard mallet and pri with levers , there are several dowels to connect cases in place and sealant !
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Do i need to remove engine studs on 1989 GSXR 1100 to split the crank case?

Usully, studs are simply bolts that have removable nuts on them. You should not have to remove the studs to split the case.
Dec 18, 2012 • Motorcycles
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1989 GSXR 1100 splitting the crank case?

answered my own question. No you do not have to remove engine studs to split the case. You do have to make sure that all of the case bolts are removed, even if they arent in the manual.
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My kx125 2002 has a funny rattle when idleing on the magneto side

Take the cover off the magneto side by undoing the 8mm bolt/screw heads around the cover. Hold the magneto firmly and try and move up and down, if you sense any movement that isn't rotary it may be your main bearing that needs replacement, this sounds like a rumble rather than a rattle when the engine's running.
(does it make the same noise when you pull the clutch in?)
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Big end bearing has disintegrated. What is the easiest way to strip the motor & remove crankshaft

If it's a 2-stroke, you'll need a crank puller and a case splitting tool to get this done, the crank is press fit into the magneto side bearing. If it's a 4-stroke, no special tools are required. Always pull the clutch side case off, leaving the transmission and crank in the magneto side. It's way easier to keep the transmission organized this way. Good luck!
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Quad wont start got spark got fuel and got compression

If it's a 2 stroke you have a crank seal out. It can have compression but won't have vacuum, and it won't run. Sometimes the seal can be replaced on the magneto side without splitting the cases, but I'd rebuild the entire motor and replace the crank bearings along with the seals. Good luck!
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Splitting the case on an 02 rm 125 got all the bolts visible on outer case just wondering if theres bolts under the clutch housing to be undone before i split

Normaly you can remove the left crankcase on its own, however if it is proving difficult to split it is possibly tight in the crankshaft main bearing, you will need to remove the clutch at some point during this rebuild so do it now while you have the stability of the engine cases , undo the nut securing the crankshaft pinion on the r/ h side, the crankshaft is often easyer to remove from this bearing, also it is easyer to reasemble the engine and gearbox when previously dismantled correctly. Paul
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I have no fire

Being that this bike is vintage. You prob have points if not then you have a magneto and coil on the left side you will see wires coming out of the case by where your foot would be. There should be like 6 or 8 phillips head bolts to take case off. Look and inspect and see if maybe you did not tighten the magneto by the flywheel it should be two screws. Try that if the doesnt help. try to jump across the coil from one side to the other see if it fires. If that doesnt help. You may need new cdi box. If theres points I cant help you much never dealt with them much myself sorry. Hope this helps ya.
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