gaj1917

Yes, getting the covers back in, with new gaskets attached is tricky. Two sets of hands helps. And, stick the gaskets on the cover grooves with a sticky gasket sealer before installing. Once the covers are in place, check and double check that the gaskets have seated properly.

There's this puller on Amazon: https://www.amazon.com/OTC-Master-Bolt-Grip-Set/dp/B007X70NO6/ref=sr_1_11?keywords=bolt+wheel+puller&qid=1579384487&sr=8-11 Seems heavy duty, and has good reviews. Not cheap.

I plan to upgrade the starter clutch on my '84 with a DanO kit. I'd appreciate advice on removing the stator, especially a puller recommendation. I have a compressor and impact driver.

Ouch indeed! Not many other options though. I've used this little J-shaped booger and it does the job. Mighty tight quarters to work in though.

Probably. Fortunately, I live near the US border, and can have items shipped to a border town where I can retrieve and transport back to Canada.

I've purchased OEM from Partshark.com in the past. Valve cover gaskets seem competitively priced at $24.85 x 2.

Thanks. Have done that too when re-lubing, but in the case of my friends '84 we'll be replacing the entire speedo cable assembly with new. Fun and games.

Now that's a good and timely piece of advice. I'll try that. Will be helping a friend replace the cable on his '84 and wasn't looking forward to getting up in under the instrument panel to remove the old cable and install the new.

If it was a seized speedo I think you'd have heard it complaining (squealing) for some time now. At least that's what mine did before it eventually seized and twisted the cable end off.

My '84 has a reserve setting, but like BlueSky said, I need pliers to turn the little knob. I just leave it on reserve all the time. That way, any moisture that might collect in the tank bottom is drained away into the gas line filter.

Boy, you're doing a great job on that bike. So thorough. Impressive.

It’s been awhile since I repaired my 2nd gear, but I recall having to fiddle with that wheel as we dropped the bottom case onto the upper, so that it engaged a wheel on the transmission - I believe it was the 1st gear wheel but could be wrong. Anyway, make a trial run dropping the lower case onto the upper and you’ll see where things have to mess. BTW, dropping that lower case is a two-person job to make sure the shift forks drop into the correct slots.

Outstanding! Not so bad is it. If you plan to install the -hammer's '87 transmission, you will need to retain your '83 middle gear components. Otherwise I believe you'll get into gear lash problems. Someone here with more insight may have another thought on that.

When I did my 2nd gear repair I replaced the clutch springs and plates with new Barnett brand ones. Made a world of difference as I was experiencing some slippage before. Often times though, just replacing the springs will suffice.

Alright! That's the spirit.