• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Slick engine case removal trick needed

  • Thread starter Thread starter Flaggo60
  • Start date Start date
F

Flaggo60

Guest
I'm finishing off changing all the case screws from the use-once beauties that were installed at the factory to stainless Allen bolts on my 81 GS650G. Since the left engine casing cover has never been off, its stuck solid even though I've drilled off the heads of the remaining stuck four original screws and removed the new Allen bolts that were installed there as well.

I want to get the cover broken free without gouging it up to do it. The gap is quite small and a screwdriver would just make a mess. I have a new gasket ready to install, so I'm not worried about that, but is there a slick trick to moving a stuck case cover that's been in place for 28 years?
 
wack at the case with a rubber mallet or dead blow sand filled hammer. that should loosen it up. what cover are you removing?
 
first timer said:
wack at the case with a rubber mallet or dead blow sand filled hammer. that should loosen it up. what cover are you removing?
Click to expand...

I have a few seized screws on both the left and the right side engine case covers, so both. I tried the rubber mallet bit and it just seemed to bounce off, but I'll give it another try.
 
Answer: There is no slick way to do it. I beat up on it with a rubber mallet which may have helped. I ended up using a sharpened wood chisel, and carefully tapped it into the gap. This opened it up and eventually the casing cover came off.
 
The problem you are experiencing is the corrosion on the dowel pins holding the covers tight. Wood chisel will work wonders. Ray.
 
rapidray said:
The problem you are experiencing is the corrosion on the dowel pins holding the covers tight. Wood chisel will work wonders. Ray.
Click to expand...
Agreed. The dowels are located one at the front kinda toward the top and one on the bottom i do believe. You can kinda see the hump where they are. The wood chisel Ray suggests works fantastic, just be patient and try not to gouge the gasket mating surface up..Also, if you're speaking of the Stator cover when you say LEFT CASE COVER dont forget that you have a big magnet in there trying to fight you too...Just take it slow, you will succeed!
 
If you must use a wood chisel, use it on a spot that is double sealed, ie., there is no oil directly behind it. The front dowel bolt area is a good place. Also, the rear of the stator cover has an oil-less chamber where the wires exit. The only other places would be round domes around the remaining bolts. Just break it loose a little, then use the rubber hammer.
 
TheCafeKid said:
Agreed. The dowels are located one at the front kinda toward the top and one on the bottom i do believe. You can kinda see the hump where they are. The wood chisel Ray suggests works fantastic, just be patient and try not to gouge the gasket mating surface up..Also, if you're speaking of the Stator cover when you say LEFT CASE COVER dont forget that you have a big magnet in there trying to fight you too...Just take it slow, you will succeed!
Click to expand...

That huge stator magnet was exactly the cause for the resistance I think. I did get the case cover off and there was no damage, so thanks to all for their suggestions.
 
You must log in or register to reply here.
Back
Top