opcorn I'm ready to learn something.

 

I know you say you have taken all the bolts out, but ...

The only times I have ever found a component stuck as fast as you describe have been the times when I have stopped, reconsidered, and then found another previously unseen bolt.

Just sayin' ...

 

On a constructive note, have you tried heat? A kettle of boiling water over the cover might help to free it.

 

I use a rubber hammer and hit it on the sides tap around the cover till it moves then pull out on it ,the magnic is strong you will have to pull it out of the rotor.

 

That was the first thing I tried, glad I'm not crazy.

This cover is certainly behaving as if a bolt is still in, but this is a design where there aren't any hidden bolts. Can't tell you how many times I stopped to check that they were all out. I'm wondering if the locating pins are seized somehow.

I like the kettle of water idea, but I think it'd be easier to just run the engine until warm. Think I'll put all the bolts back in at about 1/4 the torque setting, then run the bike until the engine is hot and try again.

Many thanks for the suggestions so far.

 

Boiling water on the cover will expand only the cover, and the differential expansion may crack the thing that's sticking. Warming the engine will expand everything equally, and may not be as effective.

 

Try using a putty knife and tap it into the the seam gently with a hammer all the way around to separate the gasket. Then you should only have the magnetic force holding the cover on.

A putting knife is thin, so it will penetrate easily and it won't pry it away too much in one place causing warpage.

 

Bigger hammer?





Longer swing/run up?

 

I just went through this on Saturday. Mine was stuck like yours. I used an old thin kitchen knife, very thin at the cutting edge, and set it between the gasket and cover. Then just tapped it (a few hard taps) and it started to separate. Just moved the blade a little and repeated. Worked like a charm.

 

Got a new wooden dowel, snugged up the bolts until they were just a tad over finger tight, then went for a 20 minute ride around the neighborhood. My pickup coil is dying and the engine misfires badly as it heats up, and the engine died just as I pulled into my driveway -- timed the ride just right.

Pushed it into the garage and pulled out all the bolts as quickly as I could. Tapped around the cover with my deadblow (did nothing), then used the dowel and sledge technique. Just a few light taps and the cover popped! Victory is mine!

So whatever gasket/oil **** was glueing the cover on was meltable by engine heat. Good to know for future reference, I'm very fortunate my engine still ran. Boiling water may have worked as well.

PS marc hanna/Mark66 -- Just FYI it is generally not recommended to put anything harder than alumimum in between the machined mating surfaces, as you may nick them. Sometimes it is the only option though.