Engine Cover Removal

[rickt]

After a bit of sanding and polishing on the '78 GS750 left-side engine cover, I decided that it must come off the bike in order to be polished appropriately. Only one screw resisted the impact driver and had to have it head drilled off. Now, the challenge is how to get the cover off. A dozen good raps with the rubber hammer did nothing. I ran a razor blade around about a third of the union between case and crankcase and realized that this baby if not coming off without a fight! Anyone have any suggestions on how to free the cover. Is there a magic liquid that I might apply to that very thin 29-year old gasket that might soften it enough to release the case?

All suggestions are appreciated.

rickt

[chef1366]

This is the stator engine case cover. The stator and the rotor are held together by magnetic force. You really have to give it a good yank to break the force, Luke.

[chiphead]

Try using a plastic headed hammer instead of a rubber hammer.

[Pearson]

After a bit of sanding and polishing on the '78 GS750 left-side engine cover, I decided that it must come off the bike in order to be polished appropriately. Only one screw resisted the impact driver and had to have it head drilled off. Now, the challenge is how to get the cover off. A dozen good raps with the rubber hammer did nothing. I ran a razor blade around about a third of the union between case and crankcase and realized that this baby if not coming off without a fight! Anyone have any suggestions on how to free the cover. Is there a magic liquid that I might apply to that very thin 29-year old gasket that might soften it enough to release the case?

All suggestions are appreciated.

You are about 2 weeks behind me :-D . Read thru this post:
http://www.thegsresources.com/_forum...d.php?t=101434. There's alot of info on removing this cover that's aka the alternator cover, magneto cover, stator cover, stupida$$ cover that won't budge...and alot of other names that are nonprintable. Bottom line is to keep at it with the rubber hammer, good clean hands/rubber gloves to get a really good grip and pull straight out like Chef said. Those dowels are also probably corroded. If you haven't ordered the replacement gasket, better get on it. Takes about 2 weeks. Also, carefully note which screws come out of which holes if it's not too late.

[jbs80106]

my inputs

after readiing the referenced thread on the subject...just kept wacking away on it with a rubber mallet and low and behold it came free! Been busy with other stuff so haven't replaced the stator or anything else yet.

One related question, dude at the Suzi dealer parts department said that in their shop they put the new seals in dry?!?! But then I've read to grease it before putting the cover back on......

hmm