From reading posts on this board and others, it seems that a lot of people are reluctant to do a bottom end rebuild for the first time. I actually think the bottom end rebuild is easier and more straight forward than the top end. I did two bottom end rebuilds on my FL350 motors this weekend. After I did the first one I decided to photo document the second to show how easy it actually is. The only special tools I used was a seal driver that you can pick up at Harbor Freight tools for about $10.00.

Hmm. when I previewed my post the pics and comments were in the correct order, now that it is posted it is reversed. What gives?

Now you should have both bearings on the crank.

Choose the driver that is just a bit smaller than the opening

Next use the seal driver and gently tap the seals into the side of cases. I tap them in dry. The times that I have lubed them, I could push them all of the way through with finger pressure. So I don't do that any more.

Next take the deeper of the two case halves and put it in the oven set at 250 degrees. The halogen light will not get the cases hot enough so you have to use the oven. It is best to do this when your wife is not home. But if you have done a good job of cleaning your parts then is should not be a big deal if you get caught. After it is hot just place the crank, bearing and all in place. It will fit right in. No tapping or banging required. Also while the case is still hot place the balance bearing into its hole. The one is a bit trickier since it is small and recessed deeper in the case and the case is hot. Use gloves and be careful.

Now once the case half and the bearing temperature has equalized, drop the balancer in place. Now heat the other balancer bearing under the halogen light then put it on the exposed side if the balancer. Also at this time it is a good idea to put in the dowel pins and then set the case gasket in place.

Tap the other case seal in place and then put this case in the oven again at 250-275 degrees.

When this side heats up put on some good gloves and place it on the case and crank assembly. It too will go right on without banging but since you have to align both the crank bearing and the balancer bearing you will need to gently work it into place with your hand pressure. A little back and forth pressure pressing down will get it done.

There are nine bolts that hold the two case halves together. Seven are 65mm long and two are 70mm long. The two 70mm go in the same homes as where the dowel pins went.

Torque to specs and the bulk of the work is done. Next weekend I will finish the accessories and then the top end when I get it back from Hoser

awsome tutorial but i think the thing that makes people reluctant is the dissasembly. What tools do you use for dissasembly.I would do it myself if i had the tools. Where do you get the flywheel puller and the case splitter.

nice write up

Awesome work Greg and GREAT pics!

I still think this board needs a "HOW TO SECTION"

Most other forums I belong to have a how to section. Members can do exactly what you did and then have a MOD approve it and it gets posted in that section.

Here is an example: (this is one of the Lightning forums I belong too) How to is at the top of the page.
http://www.svtperformance.com/forums/2nd-generation-22/

Rocky Mountain http://rockymountainatv.com ATV has the Flywheel puller.

As to the case splitter, I have never used one. I just put the whole stripped assembly in an old gas grill heat to 250. If you look at my the pics in my last post, where I had just put the two cases together, before I installed the 9 case bolts and imagine that you were at that stage of dis-assembly, now heat the whole thing in the oven, it comes right apart, nice and easy.

Are you adding your pictures in the order that you want them to appear? Do the picture you want to be on top of the list first, then in the box with that picture add the text you want with the pic.

You can go back and edit each post delete a pic then re add the pic in the right order also.

Very impressive job! I was going to do it on my next bottom end but it would not have been that good. Thanks for posting it.

Gary

Thanks hoser,

I did not know I could go back and edit a post. I will do that.

Greg

Greg
Great write up I wish I did not drop my Engine off now...I would love to see the wife's face when opening the grill
while I was heating the Lower end
Go Oddy

I can tell you her response would not have been all smiles and giggles and telling you have much she admires you for your ingenuity.

It would be like her going out to your shop and using one of your straight edged rulers as a pry tool to get a spoon out of the garbage disposal.

I'ts best done when she's not home and just say, "what smell?" when she comes home.

Deny, deny, deny.

Greg

don't forget to brush some oil on all the seals (at the friction pionts) before assembly, this will add hours and hours to your seal life. Forget beef...Crankcase "its whats for dinner"!! Very cool write up indeed.

I use grease.