Oh, what have I done

[Oldseadog]

It all started innocently enough. The aluminum crank case covers look bad, so I removed them to polish them up, while I was at sea. I removed the water pump cover, clutch cover, plus the small rear one on the left side (transmission?). I couldn’t get the large front one (stator?) off at the time. While I was waiting for the gaskets to come in, I worked on the large cover. When I finally removed it a small gear fell out. I was able to put it back, hope it isn’t supposed to be in a certain way. I went to remove the screws holding the wires to the cover but no luck. I have the right size screwdriver, but they won’t move. I stopped before I stripped the heads, but I think it won’t take much force before they are striped. What is the easiest way to get these screws out? I can’t get the cover to my workbench, as it is still attached to the bike by the wires. It is free to move around as I try to break the screws free. I tried hammering on the screwdriver while twisting, but was getting nowhere. Help I don't know where to go from here.

 

Bill

[cimmer]

You didnt state what year bike, but the wires from the stator cover go to your regulator. There should be a connector near or on the regulator that you can disconnect and that should let you remove the cover from the bike. Just trace the wires and you should be locate the connector fairly easily.

Good Luck,

Rick F.

[dingy]

A well fitting hand impact driver. Get a decent one, like Sears. Harbor Freight bits are slightly stronger than a licorice stick.

 

Gary

[uncledj]

Not sure without looking what the screw heads look like, but most phillips head screws have enough of a head to grab with a pair of vice grips. It usually mars the screw head a bit, but it usually works for me.

[Oldseadog]

Thanks for the quick replies. I will follow the wires and disconnect them.

After doing some more research, I now know it is the generator cover, and the screws are holding in the pick-up assembly.

 

Bill

[dacheedah]

A well fitting hand impact driver. Get a decent one, like Sears. Harbor Freight bits are slightly stronger than a licorice stick.

 

Gary

 

2nd that, you don't have to drive it through the case, sharp raps

[bongobobny]

They are #3 phillips if I recall right, and they are loctited in. Give the screws some heat first but carefully. I used a hammer on the screwdriver head and vice grips on the screwdriver shaft to get them out. Yes, an impact driver helps...

[MiCarl]

The screws are not Phillips, they are JIS which is slightly different. You will only strip the heads trying to break them loose with a Phillips.

 

The Craftsman hand impact driver has JIS bits (you can turn Phillips screws with a JIS driver). After breaking loose with the impact driver you can finish removal with a #3 Phillips.

 

The screws are secured with thread lock compound and a bit of heat will help break it loose. You should use loctite when reinstalling the screws.

 

But if your goal is to polish simply unplug the 2 wire sets from the harness and leave the guts in the cover.

[Oldseadog]

Well, I won. I found my impact driver, in a box of tools from my dad. I am sooo organized!

I removed the wire sets and cleaned the case with brake cleaner. I'm going to let it dry overnight and tomorrow start work on polishing the last piece. (for now)

Thanks again for all the advice.

 

Bill

[GolfVenture]

Like to see some close up pictures when you get done.

[Oldseadog]

Yes, I'll have to do that. It didn't happen if there are no pictures.

[kevin-vic-b.c.]

Bill I would love to see how and what you are doing as my '86 requires the same treatment, you have more courage than I!

[Grump]

ugh shine do you plane to take it out in the rain? :backinmyday:we just shone boots.