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In lieu of a long story that might distract from my question... How might I fabricate a crankcase separator. The clymers manual I am using says such a tool "is simple in design" but the darn thing costs $140.

I hope I won't be doing this often, so the cost is totally unjustifiable. I got a good tip on Engine mount thrust adjusters here, and hope to get the same for a case separator.
 

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I've never had an SV engine apart, but in the old days we would use 3/8" all thread rod and plates of steel. It's a bit fiddly, but the basic idea is to use plates (steel, aluminum, even white oak) with 7/16" holes on center, narrow enough to go through the available holes and long enough to bridge the holes. You slip the plates in the holes, run the all thread through one plate and thread on two nuts. Keeping the nut on your side from turning with a crow foot you run the rod through the other plate. Now you crank on the crow foot to put separating force on the crankcase.

Like I said, fiddly. This was a last resort. I'd try tapping with a rubber hammer and maybe some gentle wedging first. Emphasis on the gentle, and be very careful with the gasket surfaces.
 

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I'd ask Zoran at twinworksfactory.com
Im sure he's done it and is very well aware of what tool is needed.
 

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Veee doesn't like my home-made separator. There's another way to do it. You can mimic the OEM case separator, but it takes more fabrication and a few long bolts. Take a look at the shop manual and see how the separator works. Use two pieces of 3/4" plywood glued together, drilled so a 1/2" all thread goes through where the drive screw for the OEM separator is. Use long bolts to attach the plywood to the case, same as the OEM. Use a fender washer between the drive nut (under the plywood) and the plywood.
 

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I don't like butchers that wedge things between cases to get them apart.
this is not tractor. but, like you said, you never had one apart, you just giving advice.
 

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In my 46+ years of working on bikes and cars (my first bike was a 1947 Indian Chief) of a variety of makes and vintages I built up some skills. It helped that my dad was a master mechanic, so I had a head start.

Note that I didn't say anything about forceful wedging, did I? I said be gentle and watch out for the gasket sealing areas. Many times all you need to start cases apart is some bumping with a soft hammer and some judicious, light wedging. A technique I've used at least dozens of times.
 

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I tried to separate the case on my old tecate 3 by the wedging method a long time ago and completely ruend the motor. I'd listen to Veee on this one.
 

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In my 46+ years of working on bikes and cars (my first bike was a 1947 Indian Chief) of a variety of makes and vintages I built up some skills.
I would fire your ass first day if you would do something like wedging cases in my shop ;)
in all those years you have not learn basic things, like how engine gets lubed.
you have never seen sv motor apart. and you are expert on it?
 

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I've never damaged or broken anything on any of the dozens of bikes or cars I've rebuilt. Not even bolts that were hard to get out. Like I said, I've got some skills.
 
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