Can An Amateur Split The Cases on '76 175cc? Or Am I In Over My Amateur Head?

Got my hands on a barn-find 1976 175cc GP. Bike has been sitting for 30+ years in a barn.

When I drained the crankcase oil a small piece of a cog tooth fell out with the oil. After Amal rebuild and new Uni filter got the bike to start and took it out for a spin. The motor is really healthy and pulls like crazy in 1st and 2nd but 3rd gear is a problem and is no doubt the source of the missing tooth. You can feel the tranny "snatching" in 3rd.

4th, 5th, 6th are fine.

Splitting cases and tranny work are not part of my skill-set. I don't have the experience or the specialized tools. I don't have any pullers. I do have the shop manual.

Question to this esteemed group is this: can an AMATEUR
wrencher split the cases on this engine, replace the bad cog, and get it all back together again?

Thanks in advance for any advice.

I would say ... yes ! It is perfectly within the realms of a reasonably competent mechanic. A must is having the manuals, which you say you have.
BUT ... having a case splitter and a tool to assemble later is a must. They can be DIY made. There are several threads with pictures on this site of ones that have been made easily and cheaply. I certainly would not go down the route of a screwdriver and hammer

The other option is to find someone near to you that has the tools etc,and would do it for you, or even better show you how it's done whilst you are there.

+1 grouty!! That can not be emphasized enough. You can also use universal case splitter that I have found to work as well as the Husqvarna specific one but is flexible enough to work on non Husqvarna projects as well. Also on that series engine it is imperative to have transmission in 4th gear to make sure it is synchronized properly.

Yes, there is enough of us to coach you through it.

There all kinds of little tricks to keep things in order.

I band my gears and shafts together with tip ties. Same with shifting forks needing properly placed.

Like they say:

Step one get universal case splitter.

Thanks, guys. You've inspired me to give this a try. Will check out some of the home-made case splitter designs on this site and try to fabricate one of my own.

Appreciate the advice you've offered to this point. I'll no doubt be needing more as I step through this. Binx

Jim.. it is the step feeder that must be syncroed correctly.. ansd isn't it supposed to be set up in 3rd gear??.. or that only for the 5 speed engines...

I am sure it is 3rd for 5 speed and 4th for 6 speed in the non primary kick engines

I would advise you to bring your patience along for the ride. You may find that sometimes it's best to walk away when things aren't going well. Never use excessive force, if it's not coming apart, STOP, ask those that have been there before you and before you know it, you'll be riding with a smile on your face:-)
W

30 plus years?
gotta get the barrel off first...............

Patience will be key to your success!

There are some good guys here who can and will offer their assistance and advice, the best advice so far is from grouty in post #2!

I can add that the cases can be as soft as cheese, so the right tools/techniques are a must, inside they're not very complicated but take LOTS of pictures, the manual assumes you've done it before and kind of jogs your memory, it's a bit vague, and an aftermarket manual is just a basic reprint. Big close up digital pictures will make reassembly a snap, once you get it apart that is......

I knew abloke who miged a lump onto his gear set made a metal profile and stoned another tooth out of the mig weld, that was the night before a long distance trial. He completed the trial and as far as i know the bikes still got a migged tooth.?!?

Wouldnt recommend it tho.
You can strip anything down with enough patients you can build anything back up too.
We all started somwhere at least your willing to give it ago, got plenty of mates that are too afraid to spanner on their machines.

WELCOME TO THE FOLD!

So where do I get a replacement gear for a '76 tranny? Am assuming I can't just call my local Husky dealer and order something this old. Or can I?

Will probably also need gaskets.

Here's a pic of my air cleaner. Possible this was a trick race mod in the day? Running a mouse nest instead of a Twin Air or Uni?

Try emailing andy at hva hes a sponcer on the site.

Those filters are the same up to and including 1978. Yes, Andy at HVA has them. Judging by the filter I would say a "surgical" rebuild is on the cards. Who knows how far the mouse got ! Maybe the basement was the latrine ! You may find the penthouse suite was on top of the piston if the ports were open .....

Looks like a fun rebuild. Don't forget - we need pictures

I just bought a 400 lc with an air box looking like that. My motor is stuck and the reed frame is gone from the urine. It ran into the crank too and now I need crank bearings and lower rod bearing. I still haven't got it apart since I need to make/get a case splitter too.

ive thrown away a few cages like that..