Hello
I have a 1984 xt 600 I have the engine on my workbench, with the head off, clutch off, I need to split the casing, my kickstart blew apart breaking my right inside casing in 2 places.
I am either going to have the right side casing welded or buy a used right casing.
Could someone guide me on what to do split the casing please I have never done this.

I'm in the process of splitting a spare bottom end - first time on my own, HOWEVER, I have 'assisted and observed' on the procedure before, so here's what I learnt (I'm sure some of the veterans will have their own tips & methods)

1. Say a prayer to the XT Girl godess. :-) Say sorry for breaking the pins off the clutch basket.

2. Make sure you have a piece of cardboard handy, where you've drawn an outline of the crank case and have holes for the bolts. This way, you can save the bolts in the right places, as they come off.

3. Started with the LEFT side case on top. Loosening all the bolts in a criss-cross pattern to avoid warp. Think there's 8 bolts.

Best to rest the engine on something that lifts it off the work surface a bit - else it wobbles around. I have wooden blocks.

4. Do same with right side. Think there's 6 bolts. Once all the bolts are out...

5. There's places built into the cases, where you can use leverage - I use a wooden block and a little baby hammer ... and gently tap until you break the gasket seal... (Theoretically! )

How much force you eventually use is totally up to you and your CONSCIENCE. But obviously do NOT try and pry it apart with sharp objects or you'll just damage it and then they're useless.

At this point, I usually get someone else to do it, so I can blame them if something gets damaged. But only girls are allowed to do this. So you just keep prying and tapping till you succeed in getting them apart...

You should be able to lift the right side off, without disturbing all the stuff inside...

Hope this helps???

Good luck and pleeeeeeease let us know how it went...

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PS - Just thought - my stator has already been removed - not sure if you have to do this before splitting?? Will check my manual & let you know.

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Have you actually stripped a rebuilt and XT engine yourself ?

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Yamaha TT600RE 2004
Yamaha YZ250 2 stroke 99