Crankcase Problem

Hello,

I've got a problem here on my engine after a rebuild and it is baffling me quite a bit so I am going to try and get some advice and help here from you guys. I've had some experience with SV650's for about three and half years now but never had this problem.

Right the model is the carb version and here is my problem;

I've stripped the engine down to inspect the gearbox and replace the big end bearings on the crankshaft. This all went fine and the gearbox was well lubricated as was the crankshaft and driveshafts and selector drum. Sealant was applied to the cases and the other crankcase half was lowered on and after ensuring all the shafts were properly in it was sealed and the crankcase bolts were torqued up. The crankshaft rotated freely and everything seemed fine.

This was fine except one of the selector forks has jumped out of the selector drum and was fouling on the gearbox. This resulted in gearbox not being able to move freely so the crankcase bolts were undone and the cases split again. The selector fork was respositioned back into place properly and everything was relubricated and sealant applied to the cases again after being cleaned up. Now this is where it gets interesting and pretty damn frustrating on this end.

The cases go down well up to a point and then they stop. They won't seat properly against the other half and stop short about 10mm or so no matter what. I have tried just about everything and looked at everything and I just can not figure it out. I have tried over and over to make sure they shafts are parallel and as far as I can tell they are. But what makes this especially frustrating is that they cases sealted perfectly fine 5 mins before and after they were taken apart again nothing was taken out of the engine and nothing was put into the engine. I have checked and rechecked again so now I'm looking for help or any other little tricks from some people with more expereince than me on this issue. I've never had this happen before and I've split and rebuilt about 10 engines with no problems.

Remember the cases went together fine before and the crankshaft rotated fine. To save some time on questions I'll try and answer a few before hand that I might get.

1. Yes all the shims are in place and the thrust washer.
2. Yes the crankcases are both from the same model and were fine before hand.
3. Yes all the bearings are the same code and colour on each side of the crankcases.
4. I have attempted to heat one side of the cases up to reseat them with no success.
5. The dowls are fine I have tried it with them out, swapped around and replaced but the result is the same.

So I'm at a loss here, any and all advice is welcome!

Thank you

I had the waterpump plastic sprockety thing causing a similar issue as it wasnt meshed with the gear from the crank.

After much messing around lined it up and it went in

I would understand that and check that but the crankcases are at their bare bones. The generator cover, clutch cover, water pump and cover are all off the crank cases at the moment. As is the oil pump and oil galleries. There is nothing else to take off the crankcases to reassemble them.