FZR400 rebuild: Can't crack bottom case and have a crappy manual. After help

[lazaah]

Hello,

After a few years sitting dormant, my mechanic friend has offered to help me rebuild my FZR400-3TJ ('92). Suspected run bottom end bearing. We have stripped it down following the manual (pic's attached), but we just can not seem to split the bottom case from the mid. We have taken from utmost care, to a bit of brute force, from razor blades to case splitting tools. No luck. As far as we can tell we have all the bolts out, it just seems as though the gasket is a hell of a strong glue or something.

Any ideas?

Also, if anyone has a better copy of the manual, it would be much appreciated.

Cheers

Edit: appears I can not upload images just yet

[Scouse]

Hodor.....

[Akzle]

get a bigger fucken hammer.

[Grumph]

I'd put good money on there being at least one bolt you haven't found.
Yamaha are the masters of the hidden case bolt. It's been a while since I was into an FZR400 but strip the cases right out as far as you can, oil pump out etc as under the pump is a favourite place for a case bolt...

[pete376403]

had a similar problem with an fzr1000 - had to remove the head and cylinder block to access some additional bolts going from top to bottom case

I have haines manual that covers the 600 / 750 and 1000 if any use

[cs363]

+1 On above two posts, haven't been inside a 400 but most of the similar Yammie engines I've seen have two bolts under and hidden by, the cylinder towards the middle. Bolt under oil pump is generally well hidden, inside a deep hole.
If you find above bolts and still can't split it, check carefully for any bolts you might have missed before getting violent with it....

[husaberg]

http://www.carlsalter.com/motorcycle-manuals.asp
http://www.carlsalter.com/yamaha-service-manuals.asp
its here
http://www.carlsalter.com/download.asp?p=1771

[eelracing]

Don't forget any of these suckers as well...

[husaberg]

http://2fiftycc.com/index.php?resour...ies/fzr250.34/

http://manualmachine.com/yamaha/fzr4...ce_manual_ch4/


Just as an aside you have removed the rotor and stator aye?

[lazaah]

Cheers for that, will have a little look around.

Motor is already stripped right down, oil pump out, heads off, stator off, starter clutch/gears off.. everything is off following manual procedures. Sure there were plenty of hidden bolts like you guys say - But as mentioned we have the genuine workshop manual here and its very good - it mentioned all the hidden bolts.

So will go over it again and double check for a missed one, But we have done this a few times now and can't spot any bolts left. But will keep looking, will download the attachments some of you have given and give them a look too, might help.

You can get a gap started at one end of the case with a case splitting tool, but the rest is very reluctant even when getting a razor blade or something in there to try break the seal.. see how we go.

Grumph, this is Kai actually on Lazaahs account - I'm pulling the motor apart for him I might email you direct for a few more questions

[Grumph]

Having a reaquaint course myself - just split the first of the 600's. Have you found the two bolts at the front - one in each engine mount boss ?

Which end is it you can open ?