Mcelroy434 Posted January 16, 2019 Share Posted January 16, 2019 Ok, so I am almost certain I have every bolt out (referenced both Haynes and OEM manual) including the one behind the clutch and the nut behind the clutch and under the final drive sprocket. The retaining plate over the drive sprocket is off and the plate on the input shaft is off. I have tried both pry points lightly and seen the case separating by about half a mm in that area, but the thing won’t come apart! Is there any tricks I am missing here or possible causes? Thanks for any advice Quote Link to comment
davecara Posted January 16, 2019 Share Posted January 16, 2019 10mm nuts inside behind the clutch basket? Quote Link to comment
psychodad Posted January 16, 2019 Share Posted January 16, 2019 two bolts under the oil filter? whatever you do, don't use a hammer and chisel Quote Link to comment
no class Posted January 16, 2019 Share Posted January 16, 2019 51 minutes ago, psychodad said: two bolts under the oil filter? whatever you do, don't use a hammer and chisel Oi..... it worked for fish 2 Quote Link to comment
Swiss Toni Posted January 16, 2019 Share Posted January 16, 2019 1 hour ago, psychodad said: two bolts under the oil filter? whatever you do, don't use a hammer and chisel +1 If its only parting there half a mill, it is probably those two (Allen) bolts. Quote Link to comment
Mcelroy434 Posted January 16, 2019 Author Share Posted January 16, 2019 4 hours ago, psychodad said: two bolts under the oil filter? whatever you do, don't use a hammer and chisel Yep got those Quote Link to comment
Mcelroy434 Posted January 16, 2019 Author Share Posted January 16, 2019 9 hours ago, davecara said: 10mm nuts inside behind the clutch basket? Yeah got that too Quote Link to comment
fatblokeonbandit Posted January 16, 2019 Share Posted January 16, 2019 (edited) you have taken the ignition pick up plate off ??? and dont pry the cases apart use the two 8mm jacking points that Suzuki fitted to the cases. Edited January 17, 2019 by fatblokeonbandit 1 Quote Link to comment
jonny1bump Posted January 16, 2019 Share Posted January 16, 2019 The clutch bearing keeper plate. Quote Link to comment
Mcelroy434 Posted January 16, 2019 Author Share Posted January 16, 2019 35 minutes ago, fatblokeonbandit said: you have taken the ignition pick up plate off ??? and dont pry the cases apart use the two 8mm jacking points that Suzuki fitted to the cases. Lol yeah I’m doing a full rebuild so there is nothing else left on the engine at all except what I can’t get too until splitting Quote Link to comment
Mcelroy434 Posted January 16, 2019 Author Share Posted January 16, 2019 Interestingly I just found this part photo on mega zip which is different to that in the manual. It shows an extra M6 bolt that’s inside the sump (No 4 on photo) I have only removed the 2 main crank bolts from inside the sump. Can anybody confirm there is an extra M6 long bolt that sits inside the sump footprint? Quote Link to comment
Swiss Toni Posted January 17, 2019 Share Posted January 17, 2019 (edited) Yes! That bolt secures the left hand oil drain tube to the case, but I can't remember if it's a case bolt, or just a short securing bolt for the pipe. Take it out and see! Edited January 17, 2019 by Swiss Toni Quote Link to comment
fatblokeonbandit Posted January 17, 2019 Share Posted January 17, 2019 Like toni said pull it out, doesn't appear to go right through though??? Quote Link to comment
jonny1bump Posted January 17, 2019 Share Posted January 17, 2019 11 hours ago, Swiss Toni said: Yes! That bolt secures the left hand oil drain tube to the case, but I can't remember if it's a case bolt, or just a short securing bolt for the pipe. Take it out and see! Take it out as said holds drain tube. Is very long 6 mm bolt. Quote Link to comment
Mcelroy434 Posted January 18, 2019 Author Share Posted January 18, 2019 Ok guys, I can confirm that long 6mm bolt holding the second oil tube was indeed the issue and does go through to the top case! Pulled straight apart afterwards. Very annoying since both Haynes and OEM manual do not mention it!! thanks for all the suggestions and help, hopefully this thread will serve a future first timer in an 1100 pull down! 2 Quote Link to comment
fatblokeonbandit Posted January 18, 2019 Share Posted January 18, 2019 In the Suzuki manual I have, it mentions that bolt in the section before the main crank bolts removal, it says to remove the bolt holding the oil tube in place. That's the one.. Quote Link to comment
jonny1bump Posted January 18, 2019 Share Posted January 18, 2019 At least you stoped and asked and not beat it. Joys been older we learn and step back. Quote Link to comment
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