Stuck valve cover, how to break free?

[madadam]

Hi all,

I am trying to check valve clearances on my '82 GS400T (tscc), like the manual says I should around now (~32k km). I've run into a bit of a stopper just taking the thing apart - the valve cover is stuck on. The gasket is probably original and is now rock solid... I tried wedging a plastic scraper in there, but it just broke apart. I'm very hesitant to try to pry it apart with anything harder than plastic, for fear of damaging the metal surfaces.

I've searched the forum and found lots of recommendations on how to get stuck bits of gasket off, but none on separating stuck parts. I had the same problem before with the clutch cover, but got that off by banging it with a rubber mallet. I'm not sure this approach will work here, since the valve cover seems more fragile and I'm worried about cracking it. I've tried spraying the seam with WD-40, carb cleaner, and brake cleaner, all to no avail. I've been a bit sparing with the chemicals, to avoid getting them in places they shouldn't get.

It probably doesn't help that it's well below freezing and I'm trying to work on it while it's wedged into my cramped shed.

Anyone have any ideas on where to go from here?


Cheers,
Adam

[Dogma]

I was going to suggest the rubber mallet...

Fill the crankcase with propane and light it? Maybe that's a bad idea.

Maybe pry gently on the bridge part of the cover with the mallet's handle?

[Pete Logan]

It probably doesn't help that it's well below freezing and I'm trying to work on it while it's wedged into my cramped shed.

Anyone have any ideas on where to go from here?


Cheers,
Adam

Below freezing doesn't help with brittle metal.

If it were me, I would wait for a better day, and then put a piece of wood against it sideways, and give it a couple light taps with a heavy steel hammer.

Using a rubber hammer doesn't really help, it just compresses the hammer. You need something to shift it without breaking the metal.

[madadam]

Below freezing doesn't help with brittle metal.

If it were me, I would wait for a better day, and then put a piece of wood against it sideways, and give it a couple light taps with a heavy steel hammer.

Using a rubber hammer doesn't really help, it just compresses the hammer. You need something to shift it without breaking the metal.

Thanks for the replies.

It's hard to wait for a better day since that won't come until spring... and trying to blow it off is maybe a bit extreme

I've been trying the wood and hammer thing, but was hitting upwards in the corners. I'll try shearing it sideways next.

Thanks
Adam

[SqDancerLynn1]

I would double check & make sure all of the bolt are removed

[KRISTI'SGS550]

Adam,
I have a little story that might aide in you discovering a remedy for your situation. Last week I bought a can of degreaser from Wally's World. One of those generic ones with the blue and black label. I got home and sprayed the stuff all over the engine. My engine is quite dirty and the reason for buying the cleaner was to get the grease and grim off. Well the degreaser I bought foams up really good, thus making it stay on the metal for a while. I think this is how it works. I let the foam stay a while and came back to clean the parts. Later that day I decided I had nothing to do so I would check my valve clearance. I took out my screws, the hose, and lifted the valve cover. Low and behold, the gasket (which I just installed last year) was completely soaked. The degreaser ate through the gasket. It didn't ruin it, just soaked it really well.

Maybe if you try degreaser, the kind that foams, around the gasket it will soak it up and allow the gasket to seperate.

Another thought. Could it be glue and not a gasket?

Cory

[Pete Logan]

I've been trying the wood and hammer thing, but was hitting upwards in the corners. I'll try shearing it sideways next.

Thanks
Adam

Always sideways, but sharp, light blows. You're not trying to remove the thing in one go, just dislodge it a little.

[Mysuzyq]

I would double check & make sure all of the bolt are removed

+1! Check, esp. toward the front of the engine...I had this happen once...fortunately I didn't go medieval on it when the mallet failed.
Tony.

[earlfor]

There are 14 (fourteen) bolts that need to be removed. How many do you have out?

Earl

[Suzuki_Don]

Below freezing doesn't help with brittle metal.

If it were me, I would wait for a better day, and then put a piece of wood against it sideways, and give it a couple light taps with a heavy steel hammer.

Using a rubber hammer doesn't really help, it just compresses the hammer. You need something to shift it without breaking the metal.

Be careful tapping it sideways. If there are locating dowells holding it to the head damage can be caused.

[madadam]

Adam,
I have a little story that might aide in you discovering a remedy for your situation. Last week I bought a can of degreaser from Wally's World. One of those generic ones with the blue and black label. I got home and sprayed the stuff all over the engine. My engine is quite dirty and the reason for buying the cleaner was to get the grease and grim off. Well the degreaser I bought foams up really good, thus making it stay on the metal for a while. I think this is how it works. I let the foam stay a while and came back to clean the parts. Later that day I decided I had nothing to do so I would check my valve clearance. I took out my screws, the hose, and lifted the valve cover. Low and behold, the gasket (which I just installed last year) was completely soaked. The degreaser ate through the gasket. It didn't ruin it, just soaked it really well.

Maybe if you try degreaser, the kind that foams, around the gasket it will soak it up and allow the gasket to seperate.

Another thought. Could it be glue and not a gasket?

Cory

Interesting. I'll pick up a can and give it a shot. I was hoping the carb or brake cleaner would do the same, but had no luck with those.

It's a gasket all right. I've managed to chip a small piece off with a plastic scraper before it broke.

Thanks,
Adam

[madadam]

+1! Check, esp. toward the front of the engine...I had this happen once...fortunately I didn't go medieval on it when the mallet failed.
Tony.

I keep thinking the same thing and have gone over it many times... that's not to say there's no way I have missed one (or two). I'll check again for sure though.

Adam

[madadam]

Always sideways, but sharp, light blows. You're not trying to remove the thing in one go, just dislodge it a little.

For sure. I've been tapping a few times, then trying to lift it off (just by hand, not prying it).

I'm beginning to question whether it's worth checking the clearances after all.

[psyguy]

regards the freezing temperatures - why not warm the engine up before using the mallet
i would also leave the cover unbolted, the engine vibrations should help - and if you see an oil leak somewhere - thats the spot where you want to pry the cover off

[Junkie]

regards the freezing temperatures - why not warm the engine up before using the mallet
i would also leave the cover unbolted, the engine vibrations should help - and if you see an oil leak somewhere - thats the spot where you want to pry the cover off

a warning related to this: if you don't get it fully warmed up, make sure to let the bike sit upright - not just on the sidestand - for a minute or so after you've run it. i had let mine idle for maybe 15s right before removing mine, and dumped a ton of oil down the side.