View Full Version : EVO XL case splitting pictorial (how to split rigid evo sportster cases)

02-07-2013, 6:48 PM
(the title is redundant but is google food. I know I was looking for a thread like this previously)

after you remove everything from the cases i.e. transmission, clutch, rotor, stator, cams, oil pump etc, you will need to remove your pinion gear and oil pump gear. DONT LOSE THE KEY. (look elsewhere for guidance on this and make sure you do i right. don't lock the primary side and crank the pinion nut off! you just may twist your crank!)

c http://imageshack.us/a/img842/1070/wp000627.jpg

the parts you should have in front of you..

b http://imageshack.us/a/img526/4223/wp000626.jpg

primary side is where all the screws are.

there are 3 1/4 socket heads bordering the flywheel and one long 1/4" socket head holding the cases together at the crotch of the cylinders.

there are 4 t-40 torx screws at the bottom of the flywheel.

d http://imageshack.us/a/img834/7230/wp000628.jpg

now you should have these parts in front of you

e http://imageshack.us/a/img267/8313/wp000629n.jpg

get your self a SOFT BFH, rubber deadblow or rawhide, and firmly tap the cases to separate. i tapped on the oil pump housing and the rear mount. do this in small even increments to clear the locating pins shown on each side.

once the halves are clear of the pins you can easily wiggle the gearcase side off the flywheel.

f http://imageshack.us/a/img801/8499/wp000630.jpg

g http://imageshack.us/a/img534/2112/wp000631s.jpg

oops. fergot there's oil in them thar cases.

h http://imageshack.us/a/img266/4063/wp000632.jpg

you can just barely see the locating pins

i http://imageshack.us/a/img441/9739/wp000633.jpg

set up your press. i used equal height blocks of wood as the spigot crotch on my cases is very very slight.

make sure you are not resting on your rod ends and that the flywheel has room to drop.

j http://imageshack.us/a/img145/3537/wp000635.jpg

and then just slowly and firmly press STRAIGHT DOWN on the pinion shaft until the crank falls loose. KEEP YOUR HAND UNDER THE FLYWHEElS TO CATCH THE CRANK ASSEMBLY!

k http://imageshack.us/a/img713/961/wp000636.jpg

here are the parts you should have in front of you...

l http://imageshack.us/a/img585/3580/wp000637.jpg

oooh, something shiny! backup engine pistons has gas ports, ceramic top coating and teflon skirt coating. too bad they are the wrong compression height for my heads. made 140hp with them though. problem being solved right now. custom pistons...

m http://imageshack.us/a/img844/3797/wp000638.jpg

job complete

02-07-2013, 7:10 PM
So what do i once I have it all apart

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02-07-2013, 7:18 PM
So what do i once I have it all apart

how the fuck would i know what you would do once you yanked your crank? make an planter? :D

I knew the crank was tweaked after bonneville and needed triage so I could decide what to do; rebuild the whole bottom end or throw a temp crank in the cases while the race crank was straightened out.

.018 means i am a very lucky motherfucker. lucky that i did not have a catastrophic failure.

video of how you do NOT want your crank to look but how you should expect it to look after extended 160+ mph 7000+ rpm abuse is here (http://www.facebook.com/photo.php?v=4701077079396).

02-07-2013, 8:25 PM
totally joking with you dude....

02-08-2013, 1:17 AM
Very interesting. Would love to see more stuff like this

02-08-2013, 1:20 AM
I was just messing with you too lol, but rebuilding the bottom end doesn't seem so out of my reach anymore, but I could be wrong

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02-08-2013, 1:22 AM
Very interesting. Would love to see more stuff like this

you will. there is fixin to be some engine building going on here at Desert Sky Racing :D

02-08-2013, 3:30 AM
Good thread. Thanks, man!

02-12-2013, 6:26 PM
p.s. this is the correct tool to pull a pinion gear. using jam bars is an express ticket to a fubar pinion gear. don't ask me how i know.


01-26-2015, 9:49 AM
Great thread!!! Bitpusher, for whatever reason the pics never came up. Is there a way you can re-post it or pm me. Thanks!

01-26-2015, 4:10 PM
Unfortunately, Bitpusher was killed on his bike last year. Talented dude. Shame the pics are gone, it was good tech. Ride in peace, Bitpusher.

01-26-2015, 7:51 PM
rip bitpusher, he built one RADICAL offroad sporty ,,,

01-27-2015, 7:53 AM
Oh man sorry, I did not know. RIP Bitpusher. @spent Thanks for letting me know.

01-27-2015, 11:40 AM

01-27-2015, 12:01 PM

That's Bad Ass.

Sorry to hear about his passing...