engine crank-case cover removal

[middle-aged guy]

Hello everyone - I'm a balding, middle-aged Brit living in the south of England and have recently bought an Argo Conquest (1996 year). It's got 8 wheels, not 6 - can I still ask some dumb questions?!

There are few amphibious ATVs in the UK, and what there are seem to be in Scotland and used for deer stalking - so very few indeed in the south where I am. However, in a fit of madness I have bought this machine and have now spent many hours skinning my knuckles trying to fix it! No one around here knows the first thing about these so I'm glad I found this forum.

The problem is there is a coolant leak, and this appears to be at the crankcase gasket where it is dripping down the outside. The engine is a Kawasaki FD620D.

I am trying to take the crankcase cover off so I can replace this gasket. I have managed to remove the clutch assembly from the driveshaft - which took MANY hours of banging and swearing, and have the crankcase cover about an inch off, but my question is this: can I completely remove this with the engine in place? There were two bolts attaching the cover to the Argo chassis - does the cover form part of the engine mount and will removing the cover essentially leave the engine unsupported on that side?

Any help gratefully received!
Thanks all
Tom

[BF6X6]

Good day to you sir. I would be checking around the thermostat housing at the top of the crank case cover. When they leak, it will look like the crankcase cover is leaking. It will unbolt. Three or four bolts hold it on. There is the small heater hose, and a rad hose that attach to it. That was a common spot I have seen them leak at. Hope that may narrow it down for you. Use a small mirror to look at the bottom of the housing and the top of the crankcase cover.

[middle-aged guy]

Thanks, but I've got the cover partly off now, so I'm kind of committed to replacing the gasket whatever! I suppose I'm just worried that if I completely remove it the engine will be unsuported.

[BF6X6]

No harm in that. If you get the cover off, in which you more than likely have, it's a good time to put in a crank seal in. Wish you all the best in your repairs. You are going to have fun when out and about. These machines are just too much fun to drive. Cheers to you sir

[middle-aged guy]

So, update: there was one more bolt at the side holding the crank case in, and once I removed that I thought I'd done it. Managed to slide the crank case off about an inch - and now it won't go any further. The only thing I can see holding the cover on is the crank shaft - but from all diagrams I can find online there is only an oil seal here. So what is preventing me taking the case off? I am losing my mind here, I've spent countless hours swearing at the thing - can any one help??!

[plott hound]

did you remove the key in the shaft?heres a handy video https://www.youtube.com/watch?v=EqBKQcbaodo

[middle-aged guy]

Hi plott hound, thanks for your reply, yes I have removed the key - and yes, I managed to track down that video before. But tbh that is why I'm so stumped! There seems to be absolutely no reason I can see why the crank case won't just slide off - but it won't budge. It's an inch off, all the gears are visible inside and the only thing that I can see still connecting the cover to the block is the shaft, and it won't budge. I'm tearing (what's left of) my hair out! Access isn't great around the engine but I'm as certain I can be that there are no other bolts I've missed. Any ideas?

[Dw89xj]

If you have a bearing in the case cover plate, there might be enough corrosion on the crank it won't let it slide out, did you try pushing it back together and sand the crank area with some 320 or finer to clean it up? That might be all that's fighting you, just a little bit can jam stuff up tighter than a gnats ass.

[middle-aged guy]

Thanks mate, just had another look at it and the crank that's actually within the case is a slightly larger diameter, with only a small shoulder protruding past the oil seal (if you get my drift), fairly shiny but cleaned it up with some 400 paper but no difference. It is even really stiff to get the cover back in to place now. Uughhh.

Anyway, decided to take the engine out as I'm really not winning here. Spent the last few hours making good progress but now can't see how I can remove the final few engine mount bolts - on the radiator fan side of the engine, think there are two of them coming up through the chassis/mounting plate in to the engine. I can just about feel the front one, can't see how I can get a spanner on it though. Can't even get my fingers on the rear one - disc cooling hose in the way I guess. Any tips on removing the engine?

I seem to be taking many steps back here. Rapidly losing the will! All I was doing was trying to fix the leak which I could have lived with by just topping up the rad occasionally!

[Dw89xj]

Well you're this far in may as well keep pushing. This is only my second machine but my max I found it easiest to pull the upper body and engine for almost everything in the tub. You will get it I'm sure just may be removing more than anticipated. I think it helps if you curse at it too and threaten it while working in it. At least it helps on mine. But don't feel bad I think most of us on here turn small tasks in to bigger projects than we originally planned for.

[Dw89xj]

Another thought, that bearing and crank should be an almost perfect fit to each other if you push or pull any way but perfectly straight it will bind the bearing and crank and make it not want to come off or go in but if lined up perfect should be easy to remove or put on.

[middle-aged guy]

Thanks Dan. TBH I'm not even sure there is a bearing in the cover, just an oil seal. Can't see one in the exploded view.

[plott hound]

i had the kawasaki engine apart on my '96 conquest to rebuild it.i dont remember having an issue getting the cover off.damn thing should separate easy.

[middle-aged guy]

Thanks all for your responses.
Right, its all back together and running again, here's how....
Managed to get the engine out, but that was a b@$%&@₩ of a job in itself. Rad out fine, electrics unclipped great, but the final bolt on the engine mounting plate was an absolute pain to get anything on to, managed, just, with much swearing and gnashing of teeth. So, engine on the bench and managed to get the cover off using a puller rigged up with threaded rod. Turns out I'd managed to burr the drive shaft when I'd been leavering off the driven clutch, this had then scored then finally stuck fast on the journal bearings in the cover. So, cleaned it all up, and all back together. Time for tea and medals. The only issue is I have had to use a silicone gasket sealer instead of a new gasket, so we'll have to see how that goes... If it's still leaking at least I'll be able to take the crankcase cover off without a repeat if all this faff!
Thanks all