Splitting the cases

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busa1300
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Splitting the cases

#1 Post by busa1300 » Fri Dec 14, 2018 7:12 pm

This is for any and all who have split the cases of an RZ/RD/RZV500.....
The two bolts under the lower edge of the front cylinders.
I have tried to get them loose, but they seem to want to stay where they have been living for the past 35 years.
I have tried an impact driver with no luck, and I'm worried I will round them out with much more force.
They are pretty long, so I'm not sure how much heat it would need to get all they way to the threads.
Possible worse case is either weld a nut to the top to get a better bite, or cut across the heads to get a big flat head screwdriver bit onto them....?

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78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

Linx
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Re: Splitting the cases

#2 Post by Linx » Fri Dec 14, 2018 8:55 pm

I'd soak it in PlusGas for a couple of days and try the impact driver again. Make sure you've got a good fitting hex bit. I've had good success after hammering in a slightly larger torx bit for extra bite too.

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:smt006 Current Bikes
1984 47X RD500LC, 2018 Triumph Speed Triple RS, 1999 Honda CB600F Hornet
Past Bikes Include
RD250LC, RD350YPVS LC2 Race Bike, RD350F2, 1976 CB400F

gpaddict
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Re: Splitting the cases

#3 Post by gpaddict » Fri Dec 14, 2018 11:19 pm

Drill the head off, split the case and then weld a nut to it when the tension on the threads has relaxed

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tacky1
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Re: Splitting the cases

#4 Post by tacky1 » Fri Dec 14, 2018 11:24 pm

Ive opened a lot of these cases and I use a large round punch, Place it perfectly flat on the head of the bolt and give it a good crack of a hammer, Then put your Allen wrench into it and loosen away. Never had one fail yet....
If it does fail, I would drill the head off, separate the cases and grab it with a good square nosed vice grips and loosen it...
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

Linx
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Re: Splitting the cases

#5 Post by Linx » Sat Dec 15, 2018 7:11 am

It's going to be very hard to get at with a grinder without damaging the case [emoji848].

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:smt006 Current Bikes
1984 47X RD500LC, 2018 Triumph Speed Triple RS, 1999 Honda CB600F Hornet
Past Bikes Include
RD250LC, RD350YPVS LC2 Race Bike, RD350F2, 1976 CB400F

steveho
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Re: Splitting the cases

#6 Post by steveho » Sat Dec 15, 2018 8:38 am

+1 for drilling the heads off. I did this last week. Straight-forward.
Once the cases were split, I could unscrew the shanks of the bolts with my fingers!
I will not use button heads when re-building, as standard cap-heads do not protrude above the base gasket surface—-just. :cool:

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tacky1
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Re: Splitting the cases

#7 Post by tacky1 » Sat Dec 15, 2018 11:37 am

Linx wrote: Sat Dec 15, 2018 7:11 am It's going to be very hard to get at with a grinder without damaging the case [emoji848].

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Why would you even try using a grinder in there, Drill the head off, Not grind it.....
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

Linx
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Re: Splitting the cases

#8 Post by Linx » Sat Dec 15, 2018 12:21 pm

God knows [emoji1].

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:smt006 Current Bikes
1984 47X RD500LC, 2018 Triumph Speed Triple RS, 1999 Honda CB600F Hornet
Past Bikes Include
RD250LC, RD350YPVS LC2 Race Bike, RD350F2, 1976 CB400F

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busa1300
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Location: N Indiana

Re: Splitting the cases

#9 Post by busa1300 » Sat Dec 15, 2018 2:13 pm

I mentioned cutting a slot, not grinding head off....(done successfully on previous issue bolts)
Question was asked before I made any non reversible attempt, to find the best route.
I have too much money in this to F¥€£ it up.

Thanks for the ideas
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

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Speed Freak
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Re: Splitting the cases

#10 Post by Speed Freak » Sat Dec 15, 2018 5:55 pm

I'm using the torx method for such bolts. Had some trouble with one of this bolts (2 cases) but an impact wrench solved the problem.
Impact screwdrivers are not right for this type of bolts. They are good for cross heads where the rotation leads to an axial force which pushes the screwdriver out of the head.
This is not the case with hexagon heads.
Only material of bolt and tool and the fitment are limiting the torque which can be applied.
Try to get only torque into the bolt, no bending forces. Use a T-handle instead of a ratchet or a (not too strong) impact wrench.
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busa1300
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Re: Splitting the cases

#11 Post by busa1300 » Mon Dec 17, 2018 8:36 pm

Split....

Image
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

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