Left side engine case is free - but......

[rickt]

Finally got a full afternoon to fool with the '78 GS750. The screws were removed from the left-side engine case a couple of months ago, but I was not able to get the case loose. This afternoon, after a couple of good wacks with the rubber mallet, the case came loose and my worst fear was realized - a metal washer fell out onto the garage floor. Further examination indicated that the wires (from the alternator I assume) had to be disconnected before the engine case can be removed from the bike.

Can anyone provide some instructions on what I need to do at this point to get the engine case free from the bike? I need to complete the removal the metal coating and polish the case. Any ideas where the washer came from?

Thanks,
rickt

[sharpy]

cover

Washer is from the starter gear shaft. And you can undo the stator from the cover with the 3 screws and bracket that holds the wire in tight. You might need a friend to hold the cover while you hit the screws with a impact socket. Replace all the screws with allen head bolts. Good luck

[bwringer]

Disconnect the stator wires from the wiring harness, then remove the starter cover and starter so you can pull the stator wires through.

[rickt]

I did remove the starter cover and saw that the wires run across the back of starter. I couldn't tell where they come out on the right side of the bike. Is this simply a matter of separating a couple of bullet connectors and pulling them up and through?

Although I could see a couple of phillips head screws that appeared to hold the wiring in place inside the cover, it didn't look like I would have enough free space to remove them without dangerously stretching the wires. I have one case mounting bolt on the top side that I had to drill off the head. The remainder of the bolt is still running through the hole in the case. This makes tilting the case horizontally almost impossible.

Thanks for the advice and keep those suggestions coming. I may get through this project yet!

rickt

[chef1366]

The three connections from the stator are under your air filter box. To take this box off you don't have to remove your carbs so it will be easy. You can slide the rubber grommet that seals the crank case cover where the wires come through it.

[rickt]

Well, there are no carbs and no air filter box on the bike, so the wires are clearly visible. I traced the alternator leads after work tonight and it appears that the protective sleeve carrying the three wires runs from inside the engine case, around the back of the starter motor, are hidden for a few inches beneath the engine, and up past the battery box and into a large rubber boot that contains about a half dozen wires. Inside the boot are the connectors for the three leads. So, if I understand correctly, i need to disconnect the three wires and unhook the sleeve with the three wires inside from the clips along the way. Then I have to remove the starter motor so that I can pull the leads out along with the left-side engine case

Does this sound correct?

Can I then disconnect the three leads from the inside of the engine case so that I can work on case with the polishing wheel?

All help is appreciated.

rickt

[chef1366]

Only if you remove the stator.

I didn't have to remove the starter to remove the wires.

[relic-rider]

The case was hard to remove because of the magnets on the rotor pulling on the stator. You need to disconnect the stator wire bullet connectors and remove the harness with the cover. You don't need to take off the starter. You don't need to remove the stator from the case to polish it, but it will make it lighter. Remember to route the wires through the new gasket(you really should put a new gasket on), before you install the cover.