I need one of those handy tricks

[81xsproject]

I am getting ready to do what I should have done in the first place and change out my clutch plates. I have done ALL the tricks (refurb, extra steel plate, stiffer springs) and it still slips.

So, the trick I need is a good way to break the gasket seal on the clutch cover. When I put it back together last time, I used the grey silicon gasket sealer. That baby is really on there now.

I triple check to make sure all bolts are out. I have beat it to death with a rubber mallot. I tried adjusting the clutch way too tight, engaging the clutch while whacking it. I put a rag and a couple fingers in the filler hole and pulled with all my might. I really don't want to screw-up the mating surfaces by hammering wedge-like things in between.

Anyone have any other good ideas?

[randy]

Use a straight razor blade, tap it in lightly going as far around as you can. Go gently and don't snap the blade. That should free it enough to pull it off.

[Snow]

I always just break out the rubber mallet or plastic end of a screwdriver in a pinch, working my way around the edges. Razor blade as Randy mentions would probably work better.

Make sure to be reaaaallly careful with your star-bolts - following proper tightening procedure and keep eye-checking to make sure it's going on straight. It's a lot easier and quicker to back it off and put it back on than to snap it and replace it.

[TopCatGr58]

Hey Jesse,

BEFORE you take the cover off, have you checked your cable to ensure that it's NOT BINDING or sticking?? The extra plate should have worked very well!! Also, did you readjust it at the cover, setting it a tad looser than just 1/4 turn out from seat, to ensure that the lever is fully releasing the clutch?

Just hate seeing you go back in there IF it really isn't needed.
T.C.

[81xsproject]

The cable is brand new freshly lubed and moves nicely. I adjusted it to the point that it just barly didn't try to creap forward with the clutch in in gear. They were just in spec when I checked them before the clutch refurb. I think it is just time for new disks. I just gotta get that dang cover off.

[TopCatGr58]

Originally posted by 81xsproject
The cable is brand new freshly lubed and moves nicely. I adjusted it to the point that it just barly didn't try to creap forward with the clutch in in gear. They were just in spec when I checked them before the clutch refurb. I think it is just time for new disks. I just gotta get that dang cover off.

Well, if they were just in spec, at ~2.8mm for the frictions, vs. the full 3.00, that's .20, times 8 plates is 1.6mm worth of thickness that you were missing!! The extra steel would add IIRC ~3 mm, but would not be providing it's full amount of pressure due to the worn frictions! Okay, remember, be careful with that star plate!
T.C.

[81xsproject]

Actually, I think that mine alread has one that is striped. Good thing I have the extra I bought from John. What a great purchase. I got me an extra steel, extra clutch parts and I got to disperse the extra steels like an XSive Santa (all for the cost of shipping of course )

[dewibp]

I had the same problem and someone on the site told me to use a broom handle in the hole and pry it off. It worked for me.

[dewibp]

Forgot to add tap on the cover with a rubber mallet while you are prying outward. The wood protects the threads and gives you a lot of leverage. Let us know how it works.

[mro]

broom handle in the hole and pry it off.

Have "up-graded" to a 20 inch long, one inch dia. wooden dowel.
Has to be worked into hole first time because it's just a tad too big around. Be careful to not pull bike over on top of ya.


mro
btw
1" dowel also fits thru spokes to hold rear wheel.

[Incubus]

And no more goop when you put the cover back on. I've found that a thin coating of grease on the gasket and careful torquing will eliminate the threat of oil leaks while also avoiding the stuck cover problem the next time you have to remove the cover. The one thing you can count on with this old machines is everything you do will have to be done again sometime.

Patrick

[Snow]

I spray Pam cooking spray on both sides of my gaskets when I put 'em on - gasket comes up in one piece and is reusable next time the cover has to come off. Haven't had a leaking problem with it.

[81xsproject]

Then I would have to buy a gasket

[Incubus]

Maybe not. You might get lucky and have that gasket come off in one piece. You also could buy gasket paper from you local auto parts store ad cut your own using the engine cover and old gasket as a guide.

Patrick

Edit: I forgot about the goop you put on the old gasket. Yeah, you''l probably have to buy or cut a new one...

[81xsproject]

Well, even with the 1" dowel I couldn't get it. I sat on the floor, put my feet high up on the frame and pulled as hard as I could. I was just certain that the cover was going to break. The razor blades were a no go. They just broke. I heated a couple up and tryed them and they just bent. Finally I had to go with the worst case senario. So, I sharpened a with a file and pounded it between the cases with a hammer. Man, that grey rtv is some tough sh!^.