250-500cc WR 360 case split

Hi all,

I'm doing a new con rod, bearings, top end etc on my 360 motor going into a 2000 WR 250. I'm having an issue splitting the case though. I'm using a tusk type puller and when I pull it apart it splits about 1/4" then the back starts to close back up. I closed it again then re opened it and put a plastic wedge in back and continued but then it started closing by the kick start shaft and not opening anymore. . I'm wondering if anyone has experienced this and what the solution/problem was?

Thanks! Frustrated

Have you removed the kickstart lever? If so with a wooden block hit where the nut goes when you've got pressure on the cases
My guess is your kick shaft needle rollers are binding on the kick shaft just help it along with a little love tap.

You've got the stator and everything stripped?,pictures really say a thousand words.

Yes everything else is stripped down. I've tried tapping on the kick start shaft...whatever is stuck is solid. I've done quite a few case splits and this one is an odd one. Didn't know if this case specific has issues when pulling? I'll take some pictures today as I had to step away before throwing it across shop....

throwing things offers temporary satisfaction and long term grief

Pictures. Pictures. Pictures. How stripped?
Is the gear on the ratchet mechanism removed as that could be caught.
Seriously is a whole guessing game wich was fine for the first ten guys but I'm getting tired of asking same questions.

Lol....yes I got through it today. The kickstart shaft and bearing it rides on we're stuck quite a bit. Got it apart and used the parts from my WR 250 and good to go now. The whole 360 motor is now new. Here is a pic of the case opened. You can see the wear on the kickstart shaft. Really appreciate you guys chiming in.

Remember the shim orders on the gear clusters.
That's a tidy bottom end.
Pleased someone knew what they're on about.

I agree. The shims were pretty straightforward and I had the parts breakdown to look at. What was really fun was the loose needle bearings under cog 2. Lol. Who does that anyways it's back together and going to heat cycle today and go ride a bit

Thanks juicy for giving me opinions on the 360 motor too....much appreciated. I am dialing it in. I did find out that a 250 clutch actuator arm is actually longer than the 360 arm and used it instead and now clutch pull is great. Don't know if it's been talked about here? Also is there anyone who knows the motor #'s for me to find out what year the motor is? I was told it was a 2002 but has a head with no stay on it?
I'll post these pics if it helps..... I painted the cyl head and side covers so I can't go by that....they were stripped when I got it.

look at the right inner case tag for the year
the head is a 92 as it was the only one without the bosses, most likely must have been a top end failure that caused them to replace the head

Can you show the front of the cylinder, the pipe mounting was different in 92, so that would be a tell.

looking at his pipe, pretty sure FMF did not make a Gnarly for the 92 cylinder

Nice looking bike, how she's as good to ride as she looks.
I would be keeping an eye out for a head with a stay.
It will probably be fine.

No I didn't realise the clutch rod was longer on a250 I cut and shut mine 5mm longer.
Find the biggest factor in clutch pull is leave adjustment and having that clutch arm not pulling over90.
Another member told me that many moons ago.

The numbers are Husqvarna A2 can't remember the rest but just serial # . The cylinder the pipe goes "in" and not around exhaust spigot.

It's 3h1 A2 0012

Thanks for the compliment. I have been building it up for some of the enduro series in CO and some of the HS events. I'm going against all modern in my class so I wanted to build the bike the best I could. I LOVE the motor on this. With the FBF fork and Ohlins shock...the suspension is easily as good of better than the newest stuff. Very controlled suspension and the 50mm fork is night and day stiffer in deflection and stays up in stroke better. It's riding very good so far but yesterday was a 1/4 throttle pretty much kind of day. All new motor.
The frame is the 2000 WR so it has the head stay mounts so I will look for one on flea bay or something. Need to stop spending on it for a while as wife is asking how much I've spent....haha.

Oh shoot...almost forgot. does anyone have a pipe guard for the gnarly? It is Colorado and in the past I usually go through 2 pipes a season.

Not gota clue on the pipe guard, think Hyde Do one for the 300 that may fit but I wouldn't quote me on that.
I've not bought one but if they do please point me in the right direction.

As for spending onthe bike can you put a price on awesome?

No you can't...and it's a great bike. Pretty much all new.....now I'm developing a leak in the old intake manifold...one of the few parts I didn't change. Lol. Now I have to find one of those. If I can't find a pipe guard I may make one out of carbon fiber.