Cylinder Block Removal

I've got the cylinder head off OK no problem, but now I can't get the cylinder block off. The pistons move freely up and down so I know the engine isn't seized. I've pounded the crap out of the cylinder block with a rubber mallet like the FSM says to do, but the old girl won't budge. Does anybody know any tricks to break the cylinder block free so I can get it off?

Its tough to say without knowing whats gasket material on there. the black fiber gasket was the worst thing I had to deal with. did you try the pry spots and try to work it loose that way? I have used a stiff but thin/wide gasket scraper and hammered it in before with success. just dont loose your patiance and do something stupid.....I know it can suck.

Thanks for the advice, especially the patience part. Can you tell me exactly where the pry places are for the cylinder block?

front of lower cases were the cylinder meets the cases there will be a grove thats it. Where is your manual....if you dont have one get one or find a free download.

I use a thick flat steel bar that I drilled two holes in to match up to the two 6 mm threaded holes in the top of the cylinder block. High grade bolts through the bar and into the cylinder block secure the bar.

Even force alternately applied to each side of the bar with a heavy duty plastic, not metal, hammer always does the trick without any damage whatsoever to any fins or crankcase surfaces.

I tried the prying with a large flat screwdriver, but that didn't do anything except enlarge the pry slot. I'll try the bar with holes suggestion.

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DAMM

As I said, use a very thick (and heavy) flat bar. The first time I tried a thin bar (only because I had one in my garage) but I bent both ends hitting of it with the heavy plastic mallet.

When I used a 3/4" thick steel flat bar, removing the cylinder block was easy. Again, use heavy duty 6 mm bolts and ensure both bolts are tightened to have snug fit to better transfer the upward force from the flat bar to the cylinder block.

I hit mine with a rubber mallet for hours and all I got was pissed off. Put engine in a rack and turned it upside down hit twice and it came off. I know this doesnt help if its in the bike.

I just did this, keep banging and banging. Also, I know this will make a lot of guys wince, but I very gently tapped and small flat head screwdriver in the gap. Very gently and about 4 million taps will do the trick.

If and when you split the cases, there is a bolt under the started that will be invisible. Make sure you take this out, I missed it and when I split the cases I snapped this one.

I spent literally 10 hours working on the gaskets, what worked for me was a gasket scraper for the big stuff and then a good week soak with WD40, re wetting it as often as possible. Then use carb cleaner and a scotchbrite.

ya, that black fiber gaskets are the worst to remove. :evil: