Stuck Valve Cover

[Slycox]

Edit: Got the cover off and added a few images and other questions further in the post.

Hey guys so tonight I decided to get into the valve cover and check the valve clearances. First thing I noticed was the majority of the bolts were extremely easy to loosen, a couple turns with the wrench and they came out by hand the rest of the way. I only had one that I had to "break" free. Before even getting into it I could tell a PO had done something to it due to the standard head screw on one of the chrome caps, then I noticed a smaller 8MM bolt in one of the cover spots.

Upon further inspection after removing the caps I noticed some white gunk, I am assuming a PO had using a sealant of some type on the cover. Here is what I see.





I am unable to pull the cover off, I pulled evenly on both sides, nothing happened. I attempted to lightly pry it with a pry bar but knowing how fragile aluminum is I didn't get to aggressive with it. I heated up a side a little but again didn't want to get crazy with that either until I got further input.

Could cold have something to do with it as well?

So that is my issue any thoughts would be greatly appreciated, I'll keep searching in the meantime.

 

[chuck hahn]

Looks like the typical treatment for reusing the half moons...just a tad of sealer in the U and across the top. Try a 1 inch putty knife and tap it in straight and flat with the head surface as to not make gouges. Then swing it left and right to kinda cut the gasket. Do that in several spots. Now that a lot of the grip is cut, take a dowel or hammer handle and stick it in right down the center under the cover and on top of the heads fins and pry it up. usually so good resistance but it will let loose.

 

[chuck hahn]

In my remarks I naturally gave him enough credit to know the bolts had to be removed.....He did state they all came out with fingers after being broke loose so I figured the picture was of the grey stuff before removal??

 

[Slycox]

Looks like the typical treatment for reusing the half moons...just a tad of sealer in the U and across the top. Try a 1 inch putty knife and tap it in straight and flat with the head surface as to not make gouges. Then swing it left and right to kinda cut the gasket. Do that in several spots. Now that a lot of the grip is cut, take a dowel or hammer handle and stick it in right down the center under the cover and on top of the heads fins and pry it up. usually so good resistance but it will let loose.

Ok thanks for the advice, I'll give that a go and see what happens.


Edit: And it does appear that I am missing the 2 horns that are right above the valve cover.

 

[blowerbike]

plastic hammer...use caution..

 

[Nessism]

Don't fret too much. Valve covers are cheap.

 

[Slycox]

Well its off! And it appears I did not wreck any parts, just broke the gasket free in a few places and used the wooden handle on the hammer to pry up. Thank you guys for your help!






It does appear that whatever goop they used previously did leak into a couple spots. As long as I clean it, there should be no problem?

Forgive me but I do not know what the individual parts are called.









As far as cleaning the old gasket off, I have heard a scotch pad, carb cleaner? and some elbow grease should do the trick? Would a nylon brush or even a wire brush be ok? Being careful not to mar the surface.

I can get the cover to a parts cleaning tank too, thinking that might be the easiest for that one.

Edit: How might I change the image size so they aren't to big?

 

[Steve]

Edit: How might I change the image size so they aren't to big?

Pictures are near-perfect. :encouragement:

They do fill the screen without having to scroll.

You also did a great job of putting a blank line between the pictures, to give them a 'border'. :clap: :clap:

.

 

[Slycox]

Ok for some reason they are larger on mine and I have to scroll through the picture.

 

[2BRacing]

When you refit the valve cover, just smear some grease lightly on both sides of the gasket, and do not use any of that "goop" the PO got carried away with. Next time when you remove the valve cover, this will save you the hours that it is going to take you to clean that gasket from both surfaces!

 

[Steve]

Ok for some reason they are larger on mine and I have to scroll through the picture.

One thing you can do would be the same thing that I do. :-k

In your Photobucket preferences, you can have all the pictures you upload automatically re-sized. I have mine set to 800 pixels on the long side. You can click on any of the links in my sig to see how that size looks on your screen. Let me know if you need help finding those settings.

.

 

[uk gs nut]

You have a screwdriver bit down in the head fins next to a cylinder head stud !. You might want to remove it in case it drops in an open plug hole.

 

[Slycox]

You have a screwdriver bit down in the head fins next to a cylinder head stud !. You might want to remove it in case it drops in an open plug hole.

I was wondering if someone would notice that. I did get it out with my magnet so it's all good!

 

[Slycox]

Spent about 2 hrs tonight getting the old gasket and everything else off. Whoever put it on went crazy with the goop, there was a gray layer of something on the very bottom then some brown stuff and then the gasket and what looks like more brown stuff. The brown stuff is every where, at some point in the future I will tear the whole thing down to get it all off.

 

[Slycox]

Well the bottom half is clean, there is a couple gouges here and there thankfully I didn't add to them. Took about 5hrs to get the whole bottom half clean. Couldn't feel anything on there other than what I could see. I will have to recheck next time I get out there. And I will be changing the oil ASAP as careful as I was not to let anything fall in, I still fear some particles fell down.

 

[Steve]

And I will be changing the oil ASAP as careful as I was not to let anything fall in, I still fear some particles fell down.

I certainly don't want to add to your paranoia, but rest assured that anything that fell in did not fall all the way to the bottom. Yep, it is likely still on the wall somewhere, stuck to the oil film. That crud will not be available for draining until you run the engine for a while to flush it loose.

.

 

[Slycox]

I certainly don't want to add to your paranoia, but rest assured that anything that fell in did not fall all the way to the bottom. Yep, it is likely still on the wall somewhere, stuck to the oil film. That crud will not be available for draining until you run the engine for a while to flush it loose.

.

I figured as much. I'm going to drain and fill it to get whatever if any made it down. Then after my carb sync oil and filter change.

 

[Slycox]

Another couple hours of cleaning time, this time on the valve cover and finally got it decent. It is not perfect or pretty but it is hopefully functional again. Someone had taken a rather abrasive brush to it before me but I think it'll be ok.

Couple pictures of the brown goop, I am wondering if it maybe was clear RTV or the like that absorbed oil overtime.





Couple hours work here:

 

[Slycox]

Bike is running and doesn't appear to have any oil leaks or anything and she is running great, just needs a proper sync and all that fine tuning stuff.

I do have a question regarding the chrome cap screws, I ordered a new one to replace the the odd ball that I had and it is flat topped and has the dot on it, the ones on it are slightly rounded tops and no apparent dots. It is my understanding that the dot indicates JIS. Are there different types of screw covers for the caps or are the ones I have incorrect?

Also is there a diagram showing which bolts go where? I noticed out of the 16 cover bolts some were 35mm and some were 40mm, tooks some doing but I got them back correctly I believe. Would just be nice to have int he future.

 

[Dogma]

Pretty much all the cover screws on a GS will have about the same space under the head if you just stick it in the hole. A space under the head of about twice the screw diameter or a bit less means you have the right length screw for that position.

The head shapes for the chrome caps are not that critical. Finding domed screws like the originals isn't easy. I really don't like the ones that come in the stainless screw kits (which are otherwise very nice). The sockets are too small and shallow. And they're ugly in the cap. I thought I found a source for the domed ones once, but I didn't have a link saved where I thought I did.