QuestionHi,
Trying to remove the lower crankcase cover in order to replace a stator. I have removed all bolts, the foot pedal, clutch lever, slave cylinder & bracket, cooling pipe protector, & exhaust pipe. I still cannot remove the cover. I assume the gasket seal is the problem but I cannot get a good position to try and split with a screwdriver. Do you have any suggestions, as I would not what to damage any part. Thanks in advance for any help.
Bill
AnswerBill.... I went to bikebandit.com and found some illustrations of the cover. It looks like the crosshaft assembly goes through the back end of it, as it appears to have a large round hole at the rear, down low. Perhaps that is just the clutch slave cylinder I am seeing, instead.
The cover is located on two dowel pins, one at about 9 o'clock position and the other one about the middle of the top length of the cover, as you can see in the drawing. After 20 years, the steel dowel pins will corrode into the alloy engine case and outer case holes, causing some real resistance to removal. Generally, most mechanics who are faced with this kind of dilemma will either use some heat (heat gun) and a big plastic or leather mallet to smack the cases around the edges at the gasket line. The motion is kind of an inwards strike, encouraging the cover to move laterally to help break the gasket bond and outwards to start moving the cover away from the cases.
Sticking screwdrivers in between the two parts is NOT recommended. The gasket surfaces will be damaged requiring some careful dressing up of the surfaces and some RTV sealers to fill in the gouges and depressions between the two parts which will be present, even with a new gasket installed.
In cases where you are trying to get access to part the cases, like this, I often will either remove the fuel tank (if it is pretty full) or just lean the bike WAY over on a soft surface at 45 degree angle or more, so you can gain some working space underneath.
Good luck with it...
Bill Silver
