SAWV, on 16 June 2012 - 05:19 AM, said:

Id have you buy a splitter if youre going that route. You want to push on things in a straight line. I just split the cases on a 1986 ATC 250R engine. It put up a significant argument but still only needed 10 minutes to get it done.

The Tusk case separator is a piece of shit. There are several copies of the K&L separator (the one I have) that look identical for a lot less money. Amazon and a couple other places I saw online were offering it for roughly 40% of what the K&L tool costs. A steering wheel or pully puller really doesnt work. A two leg puller works with a lot of the newer two strokes. You can find those at most Auto parts stores for 15 bucks. At that point all you need is a length of 6mmx1.00 threaded rod for the pulling studs.

I used your exact parts list on my 03 450 & it all went very well. Id recommend a new cam chain & tensioner when doing any top & botton end job. I used oem valves. Never had any problems with them. Rarely needed adjustment. Religious air filter maintience & a good seal are key for long valve life. Oem honda manuels are available on ebay all the time for $30 to $50. Just depends on when you lookin for one. Inspect everything & replace any part thats out of mfg specs. Good luck & keep us posted.

When it comes to gasket and seals, OEM is the way to go. like you said you don't want to scrimp on quality.

focus the heat to the dowels part #24 http://shop.thumpert..._MEB4E1200C.gif

Hey guys sorry it took so long for an update but here it is,

rebuild complete, breakin complete and reshimmed valves after breakin.

NOW i seemed to have missed something because after a couple hrs of riding ive noticed that my tranny oil is high and clutch side oil is low, just noticed this today, any ideas??