Stuck Case Covers

[Thanatos]

Hi All:

I am refinishing the cases on my *new* 1981 GS650G, which have suffered some corrosion over the past 5 years (when it was stored by the previous owner).

Now, all of the screws suffered from serious metal fatugiue, and had to be drilled out. However, now the starter motor cover and the alternator cover are completely stuck ... I don`t want to pry them off, but I am running out of options and liquid wrench is not helping.

Anyone else had the same problem, and if so, any suggestions?

[makenzie71]

Use a rubber mallet. Hit the covers square on a few times, then hit along the edge from all four directions. The try to remove. Sometimes it takes a few tries.

If the cover is really, really adamant, you can use a PUTTY KNIFE on the TOP seam of each cover...drive it between the cover and the case very gently with the rubber mallet. Do not do this along the sides or the bottoms because if you slip and gouge the metal, you're more likely to develop a nasty leak.

[hillsy]

Also don't forget with the alternator cover you are trying to pull the stator away from a set of pretty strong magnets - so there will be (surprisingly strong) resistance.

There is normally a protruding "lip" on the cover (usually somewhere on the bottom edge) that you can get a drift behind to tap the cover loose. Use something wooden to avoid damaging the alloy.

[Thanatos]

Thanks for the advice, I finally pried them loose. Now, after looking on cyclepartsnation (and elsewhere) I am having some difficulty finding replacement gaskets ... are they still available? If not, can I use something else as a replacement?

[BassCliff]

Greetings and Salutations!

Hi Mr. Thanatos,

You can always pick up some gasket material from your local auto supply store and make your own gasket. There's a tutorial on my website. Where's my website, you ask? Read on...

Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.


Thank you for your indulgence,

BassCliff

[Thanatos]

Hey BassCliff:

Awesome website - I think I will go to NAPA and get some gasket material tomorrow. Fantastic resource - wish I knew about it a couple months ago ...

Many Thanks.

[waterman]

Thanks for the advice, I finally pried them loose. Now, after looking on cyclepartsnation (and elsewhere) I am having some difficulty finding replacement gaskets ... are they still available? If not, can I use something else as a replacement?

They should still be available from dealers or online parts stores. If not, you can make them from readily available gasket material found at most automotive parts stores. I have made several gaskets for my 650, work just fine. The difficulty in home made gaskets is the bolt holes, I use a empty brass bullet case to punch them out.

[duaneage]

Use a cheap hand held paper punch for the bolt holes. Cost me 1.00 It also can make the larger holes by taking multiple bites

[makenzie71]

If you can find one big enough, cereal boxes make great gaskets...look for that kind of cardboard, though. Like what's on the back of steno pads and those big desk calendars and such.