Removing Covers for Polishing 1980 XS1100

[Supersport396]

Some of these are easy enough to figure out but the starter for example. one cover is part of the motor but does the other cover come off by itself or does the starter have to come out?

Also the generator cover...the stator is held with 3 screws. Take them out after the cover is loose or vice versa?

Thanks!

[cajun31]

Some of these are easy enough to figure out but the starter for example. one cover is part of the motor but does the other cover come off by itself or does the starter have to come out?

Also the generator cover...the stator is held with 3 screws. Take them out after the cover is loose or vice versa?

Thanks!

If you look closely the starter cover just overlaps the other cover to the left. Best to take the starter off first. Number 25 in the schematic is the other cover. Yamaha Motorcycle 1980 OEM Parts Diagram for CRANKCASE | Partzilla.com. You have to work that cover out slowly. It sits a bit inside the cavity it cover and has an o-ring around it. So like I said work it out slowly with equal pressure on both sides and it will come out/off. As for the generator I always remove those three screws first then remove the cover then take the bolts off the rest from the inside. Taking those three out first gives you the leverage you need to loosen them while the cover is still attached to the motor. You can then rest the cover in your lap for disassembling the rest. Have you got a game plan for how you are going to polish them?

[LAB3]

Not sure about that starter question, I've never needed to mess with mine. As to removing the stator, why not? It's only tree screws to remove so you can get it out of the way.

You'd probably send more time trying to keep it from collecting polishing compound and micro sized bits of aluminum oxide then you would removing it from that cover. Also don't forget stripping any of the old sealer that it left the factory with, many choose paint stripper for that. All in all there's no advantage to keeping it in place.

[DEEBS11]

[Radioguylogs]

Stainless steel cap screws are nice.

boltdepot.com

[Supersport396]

If you look closely the starter cover just overlaps the other cover to the left. Best to take the starter off first. Number 25 in the schematic is the other cover. Yamaha Motorcycle 1980 OEM Parts Diagram for CRANKCASE | Partzilla.com. You have to work that cover out slowly. It sits a bit inside the cavity it cover and has an o-ring around it. So like I said work it out slowly with equal pressure on both sides and it will come out/off. As for the generator I always remove those three screws first then remove the cover then take the bolts off the rest from the inside. Taking those three out first gives you the leverage you need to loosen them while the cover is still attached to the motor. You can then rest the cover in your lap for disassembling the rest. Have you got a game plan for how you are going to polish them?

Hey, thanks, I did figure out the stator thing. That diagram helps with the starter cover. The cover on the starter seems to have a different finish on it so not sure I want to mess with taking that out. The one with the o rings was what I couldn't figure was holding it in and didn't want to force it. But do I have to remove the starter to get that one off?

As far as buffing, I have a dedicated buffer and all the wheels polishes, and abrasives. Did the ignition cover & it came out great. I did try paint stripper but there does not seem to be much if any clear or coating on any of them. And they don't look awful but have the grey "staining" here and there.

Brian

[cajun31]

Hey, thanks, I did figure out the stator thing. That diagram helps with the starter cover. The cover on the starter seems to have a different finish on it so not sure I want to mess with taking that out. The one with the o rings was what I couldn't figure was holding it in and didn't want to force it. But do I have to remove the starter to get that one off?

As far as buffing, I have a dedicated buffer and all the wheels polishes, and abrasives. Did the ignition cover & it came out great. I did try paint stripper but there does not seem to be much if any clear or coating on any of them. And they don't look awful but have the grey "staining" here and there.

Brian

Brian,
The starter is very easy to remove. Just remove the cover over it and the additional bolts and it slips right out. Of course disconnect the electrical connections too. The reason I say to remove it first is because the other one you are wanting to remove has to be worked back and forth in order to work it out of the cavity it covers. As you can see from the schematic I posted there is a large o ring around the center of what protrudes into the cavity that had a suction grip on it. If it has never been removed you have to work that loose. Don't be a gorilla when removing it. Just work it slowly back an forth while applying force to remove it and it will pop loose.

[Supersport396]

Brian,
The starter is very easy to remove. Just remove the cover over it and the additional bolts and it slips right out. Of course disconnect the electrical connections too. The reason I say to remove it first is because the other one you are wanting to remove has to be worked back and forth in order to work it out of the cavity it covers. As you can see from the schematic I posted there is a large o ring around the center of what protrudes into the cavity that had a suction grip on it. If it has never been removed you have to work that loose. Don't be a gorilla when removing it. Just work it slowly back an forth while applying force to remove it and it will pop loose.

Thank you Jim, that's good help. Shop manual just says remove two bolts. big help. I don't think it even mentions the cover.