250-500cc Splitting the Case of a 2010 wr300

So ended up with this husky and its been having this problem http://www.cafehusky.com/threads/2010-husqvarna-wr-300-pushrod-breaking-clutch-problems.87805/ don'T know what too do with it and now I'm going to attempt to split the lower end and examine all the parts/look for worn bearings ect. I have never split a dirt bike case, any tips on what tools to buy to be able to apart the bottom end easily and on what components too look at for wear.

Will be updating with pictures of everything!

thanks was looking at one of those, anyone know where i can get torque specs for bolts? and a good digital torque wrench/ size good for working on dirt bikes

I have recently split my WR300 2010 engine, I did it without that specific tool but fabricating my own.

For torque specs you should have a look at the service manual:
http://www.outbackmx.com/files/Workshop Manuals/2010WR 250-300.pdf

you will need a crank puller/installer as well when it comes time to reassemble. the tusk brand one will work too..
im not personally a fan of digital torque wrenches, but i like the split beam style. cdi torque products makes a good product for the money, i guess it depends on what you want to spend. they make some snap on wrenches but buying the cdi brand saves a good chunk of money.

how are you stopping the main bearings inner race from pushing laterally against its outer race?

im sure you havent, just wondered if there was something not shown.

well washed it down and getting ready to pull the engine out
what do you guys use for gaskets on the side covers oem, or some type of gasket maker and what kind.


like on this side cover.
Also what are the two side covers called on each side of the top cylinder, and do I unscrew the bolts inside them to take the top end off or just the four bigger bolts outside the case? thanks everyone going to be pretty much ordering a whole tool kit for working on dirtbike here before the week ends.

List of ordered tools:
Tusk Crank Case Splitter Separator And Crank Puller Installer
Motion Pro Clutch Holding Tool
Motion Pro Flywheel Puller External Thread
update:
bought wrong size fly wheel puller XD

New tyres & silencer mount on the cards too mate?

okay finally an update got the fly wheel puller so I was able to pull the engine off!

tools I bought:
flywheel puller
seal puller
tusk crank installer/puller
tusk case splitter
motion pro gear jammer
motion pro clutch holder
permatex engine assembly lube
liqui moly installation paste
oem gasket kit


time to pull out the clutch components..

clutch cover off
(noticed chunk off of basket missing(on the right outer teeth) is that a bad problem?) the rest of the basket looks great tho.

oem plates and rekluse out

clutch hub out

basket is out.

left top gear is out

right gear that sits on the kick starter sleeve gear is out.

it appears it has some wear against the kick starter sleeve gear should I have them replaced?

that's as far as I got for today talked to mr.crankshaft quoted a $199.99 for my crank to be rebuild, as for the bearings/seals that goes with a bottom end rebuild does anyone know the part numbers for them?

I randomly found someone on instagram and clicked on their profile and found a picture saying "figured out why my pushrod kept breaking, because the transmission bearing was bad" most random place to find someone with the same problem finally after searching/calling everywhere, so hope that is my problem.
I might aswell rebuild the whole bottom end even though the plan was to get rid of the bike before I had to do that.. looks like I might own it for one more season, haha

great post, let us know how it all goes putting back together and how she runs after this.

Where are you at in washington ?

vancouver, how about you?


took the clutch case off

using the gear jammer to get this bolt on the gear off

bolt is off the gear


taking the kick starter bolt off and getting ready to use the tusk case splitter.