Tusk Crankcase Separator | MC TESTED

When the shop manual for the bike I’m working on calls for a such-and-such “special tool,” I relish the challenge of finding a way to complete the task with what I have on hand or, better yet, making my own special tool. But when it comes to splitting crankcases, I’m not too proud to accept that a purpose-built tool is the best solution. So when it came time to delve into the bottom end on my Kawasaki AR80, I sprang for a crankcase separator from Tusk, a popular off-road parts-and-tools company.

What a worthwhile investment! The Tusk tool costs less than a replacement piston and allows for quick access to the internals of two- and four-stroke engines via a trio of sturdy arms, threaded anchor rods, and a big central screw that presses on the end of the crankshaft. This tool exposes the crankshaft and tranny faster than a fragged con-rod, and applies nice, even pressure to the case half and crank end so nothing gets torqued or warped. It’s quicker than tap-tap-tapping on the case halves with a rubber mallet, and there’s no risk of damaging expensive (and in the case of my AR80, discontinued) parts.

Tusk says the separator works on all vertically split engines, and after successfully using the tool on several different motors, I’m inclined to believe the claim. Tusk also sells a crank installer/puller that makes reassembly a smooth operation and is likewise worth the money. Just make sure you zip-tie the small end of the connecting rod to a cylinder stud to keep it clear of the case halves. Don’t ask me how I know about that one.

Price: $59.99 Contact: Tusk Off-Road www.rockymountainatvmc.com

A professional-grade tool that’s priced right for DIYers.