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So as most of you know from my other post on the ol 300 I was having a power issue with and got that figured out, now I have a cracked case half and have to pull the motor and put everything in new cases, reinstall and put humpty dumpty back together again. I was asked to start another thread vs adding to my other so here goes.
I got a decent start late this afternoon and all I lack is pulling the starter, crankcase vent lines, bust the swingarm loose and the bottom engine mount bolts and she'll be on the table. So about a half hour or so tomorrow and I'll have her out and start stripping her down, just didn't have enough left in me to get it all out this evening lol. Getting the transfer case out was a tad of a bear but if ya hold your mouth just right and call it a certain name or two it'll come right out 馃榿! Here's a few progress pics so far from this evening.
 

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Looking at the pics , there seems to be a ring groove cut into the front drive shaft , if it grabs your finger nail when ran across then it is not going to last ---I would do one of three things , replace the drive shaft so it will hold oil and keep water and dirt out , install a 4x2 kick out at this time , or use the same shaft and pump the front diff and transfer case with water resistant grease
 

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I noticed that when I got it out but it's smooth as a baby's butt I promise, absolutely nothing there on both ends. I've got new seals for it when I ordered all the other seals and gaskets since the ones in it seem to be a little wet around them and starting to collect dirt and get that buildup started on the case. No sense in having it sitting in the floor and not spend 24 bucks and a little time changing them out. I appreciate the heads up and keen eye Fish, glad you're here and aware of my little project lol. Any words of advice when I get her opened up and start gutting it and putting everything in the new cases, things to be aware of, anything to pay more attention than normal or anything since you've done several of these.
 

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Alright, got her out! Took the new used cases outside and used dawn and baking soda with a toothbrush and detail brushes and removed all the bearings and O rings left in them, old gaskets removed, blown out and ready to go. Wrapped em up and set them to the side and started the teardown. Got the top end off and started on the right side case. Everything was rolling right along until I went to remove the clutch basket. I remembered it as soon as the case was removed and I took the bearing out and saw the nut. It had "been previously molested" when I got it and someone almost destroyed the nut and when I built it originally, I had a hard time getting it off, a real hard time. I fooled with it for almost an hour with zero success so figured I'd call it a night and start fresh tomorrow. Needless to say, I didn't get done what I intended tonight dangit. I did however get some pics lol.
 

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Back out in the shop this afternoon before the next kick in the nads hit lol. Got the nut off the crank and removed the clutch basket after about an hour and 20 minutes of trying everything, and last but not least....the Dremel! Cut a slit and careful not to get into anything other than the nut, then a few smacks with a drift punch and a dead blow and voila! Ordered 2 each from Partzilla for it and the centrifugal clutch also, so new going back on and a pair in the hole! Got everything out of the right side and almost everything out of the right until it came time to use the puller and that's when it snapped, dead in the water! So, I called it a day, mixed a stiff drink and going to watch Battle Bots and listen to the thunder and rain till bedtime lol. So stinking close to splitting cases and starting to put things in the new ones, really bummed me out, but se lave'!!! A few more progress pics for y'all. My little girl heard my vocalization when I broke my puller and had to come see what was going on with dad, had to add that pic in of the nosey little brat! 馃榿
 

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Looking good , you got it clean ----so you going to put a fresh jug and rework the head while it is down ? G+H is a good source for a bore and parts
 

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Hey Fish! No man, all that's brand new from when I did everything when I got it and bet theres not 35 hours on it. G&H did the bore and hone, complete head job (I sent new Honda valves, seals, guides and springs) and i put all new rockers and everything in the box, new cam, chain, sprocket, Namura piston and rings from G&H with the oversized bore. Everything looks amazing so i luckily don't have to fork out that junk of cash all over again. I'm going in the morning and picking up a 20mm x 1.5mm left hand thread bolt from a fastener company (Fastenall) to pull the flywheel. I was trying a different puller, that I read later shouldn't have been, that broke. I'm lucky it broke and not my flywheel so I got lucky for a change. The puller as you're aware of is nothing but a bolt so why spend 30 bucks on one I can get for 4 or 5 bucks that does exactly the same thing and not have to wait on shipping. I found one under 20 bucks from Motion Pro on fleabay, but back to the shipping thing, not waiting. My goal is to have this thing in the new cases, all put back together and at minimum in the bike and all hooked up or dang close to it by Friday and giving it a test ride Saturday or Sunday. Hopefully it won't take that long but I don't have endless time to be able to stay in the shop for 8 to 10 hours for a few days to do it, so a couple hours here and there and I should be able to hit my goal. Slow and steady wins the race. I'll be back out there tomorrow moving forward so I'll post a few more pics with an update tomorrow evening.
 

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Sounds like you got it going on ------- I am not a fan of Fastenal , around here they make you buy the whole bag or box and you wind up with a lot of waste ------then without an account they make you buy $50 min
 

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Sounds like you got it going on ------- I am not a fan of Fastenal , around here they make you buy the whole bag or box and you wind up with a lot of waste ------then without an account they make you buy $50 min

Same here, could've had a whole box of puller bolts for $20, but they had to order them.
 

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Looking good. Dang those cases are clean! The ones your replacing and the new ones both!
 

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Same here, could've had a whole box of puller bolts for $20, but they had to order them.
I am 100% sure they would not have the right size ----but Tractor supply is a good deal on bolts , they are sold by the pound , grade 5 , grade 8 and stainless ------- every time I go , I fill a bag up with mixed nuts and bolts that I use often
 

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Well Fastenal didn't have one nor could get it but since they manufacture their own stuff, for the low low price of a 250 buck set up fee I can have one!!!! 馃槼 Uh.......NO THANKS! I tried Ace Hardware and a few places around me but the left hand threads are the kicker, which makes it a "specialty automotive" item and hoping to not have to go almost an hour into downtown Nashville. I've called just about every fastener company and any other place I can think of, even the Mahindra tractor dealership up here, but didn't think about ol TSC and got one 10 minutes down the road, thanks Fish! I wish I'd ordered one and it would be here tomorrow or Thursday but didn't think it would be such a bear to find, guess I shouldn't think so much 馃榿!!!
I appreciate the compliments guys, I keep her and all my other toys clean. I had it siick and span from the initial build right after I got it and after a ride she always gets a bath and ready for the next ride. I told ya the new cases I got from PSN were clean which I was even surprised how clean when I opened the box! They cleaned up even better though so I was happy. As soon as I can get the flippin flywheel off I'll be making good progress but unfortunately I'm at a standstill which drives me nuts!!! Live and learn I guess lol, so as soon as I get that sucker off I'll post an update and as always more pics for thirsty eyes 馃憖. Oh and I text a buddy of mine that's a gunsmith and builds all kinds of bad a$$ toys about turning me one on his lathe and he said he'll gimme a buzz tomorrow and let me know the cost so hopefully won't be to much. I don't know of anyone that even has one I can borrow at this point so like I said, I'm stuck in a holding pattern at the moment and have studied and studied how I can get that sucker off without messing up my crank, which is tight as a tick in every way, but haven't come up with anything. If one of y'all knows something I don't by all means jump on in fellas, a$$ chewing or constructive criticism is more than welcomed, ain't no thin skin here! I'll update things soon guys, I appreciate y'all!!
 

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I am 100% sure they would not have the right size ----but Tractor supply is a good deal on bolts , they are sold by the pound , grade 5 , grade 8 and stainless ------- every time I go , I fill a bag up with mixed nuts and bolts that I use often

They do have good buys on bolts, an aisle filled on two sides, but not the puller bolt. Bolts by the pound is hard to beat. I bought one from ebay for $12 because the shipping was 3 days vs. 10 days at Fastenal. But with Fastenal, I could've been selling puller bolts.



It's a good tool to have, that same puller is used on a lot of machines. My Kaw street bike, '87 Foreman, the '94 300 in this thread .... etc.
 

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Hey guys, sorry for not posting anything the last few weeks but been dealing with life lol. I ordered the puller I needed after doing more looking and found one on Ebay from MotionPro for $12.78 and free shipping. I could have already been done had I did a little more searching and paid closer attention to Ebay rather than going to so many places trying to find one, Bonehead!!! Oh well, it came later part of last week and been taking care of some other things and haven't had time nor really felt like fooling with it. I'm flying out Friday for an interview in Naples Florida and going to stay with a friend while I'm there for a few days after the interview and do some crabbing and fishing then flying back the following Friday. I'll be back on it Saturday and should go fairly easy once the flywheel is removed so I'm hoping to have everything out of the original cases and starting to put everything in the new used set that afternoon or at least start assembly Sunday after church. I'll be posting more pics and updates as I go when I get back. Just wanted to fill y'all in since I haven't posted anything in a while, I haven't forgotten ya lol. Thanks guys!
 
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