Cam Cover Removal

[rickt]

The '78 GS 750C restoration project creeps forward. Since the engine is sitting in a bare frame and hasn't been started in the better part of 27 years, I thought I should check the valves before starting to put things back together. After removing all the cam cover bolts and tapping here and there with a plastic-headed hammer, I realized the cover was not coming off easily. Gentle prying with a wooden hammer handle did not release the cover.

Any suggestions on how I might break this cover free without actually breaking it?

rickt

[Steve]

Did you get all the bolts removed? :shock:

If memory serves, there should be 16.

.

[80GS750]

there are in fact 16 bolts on that cover....

as long as they are all off, it should come right off, if the gasket is holding it on that tight, just take a hammer and tap it on both sides... you should not break it,

if the gasket is on there and holding it tight enough to break the cover, than you have other problems....

best of luck,

-nate

[rickt]

Yes, I actually removed 20 bolts - 4 on the breather cover plus 16 on the cam cover.

I'll give it another wack tomorrow.

[bwringer]

If the gasket is stuck realllllllly tight, it is definitely possible, even easy, to crack the cover if you get too medieval on it.

I'd cut most or all of the gasket with a razor blade first -- just gently tap a razor blade into the gasket somewhere handy, then gently tap and worry the blade around to cut loose as much as you can reach.

[chef1366]

Use a dead blow hammer.

[rickt]

Really Stuck!!!

Yes, Mr. Bwringer, this baby was really stuck. So, as you suggested, I worked around the outer portions of the joint with a razor blade - pounding it in with a hammer wherever possible. With no signs of movement, I went to plan B using a thin and very old Army knife passed down to me from my Father more than 40 years ago. By carefully striking the wooden knife handle I was able to penetrate many places on the external part of the joint. Finally (~2 hours later) the cover was free. Immediately obvious was the fact that 25+ years ago, when the cover was last removed, the gasket was attached (at least on one side) with gasket cement. No amount of pounding would have freed this cover unless it came off in more than one piece.

Thanks for the assistance. I now see shiny and almost new (2009 miles) camshalfs. Time to measure the clearance, paint the cover, and seal it back up.