stuck sprocket cover

Hey Guys...trying to remove the sprocket cover off my 78 KZ1000 and it seems to be hung up around the gear shift, yes I removed the 4 bolts. Any help would be great!

Post edited by: crate78, at: 2007/04/14 14:26

If memory serves me correctly that cover has a couple of locating dowels on it. Also you have the clutch pushrod that goes into the clutch release mechanism. My suggestion would be to try some friendly persuasion with a dead blow hammer. That cover also tends to collect all kinds of junk that gets slung off the chain. I can't think of any other real reason why it will not come off.

I don't THINK there's any dowels on that cover,but I DO know that the seal for the shift lever(shaft) WILL grab ,and make it tuff to pull off.
If Your clutch is still hooked up,give it a squeeze and that should get the cover to move out enough to get Your fingers on it,and then You just have to wiggle it back and forth.

Whoops...yes,there are 2 dowels.:S

Post edited by: Sandy, at: 2007/04/14 14:53

Everything Sandy and The Gringo said, with one minor addition:

Depending on useage it's not uncommon for the actual shifter rod to be a little bent, such that the race around the rod hangs up a little around a slight bend.

Take a rubber/plastic mallet and and give the end of the shifter rod a *light* whack while pulling on the cover. Might need to repeat a couple/5 times.

Should come right off.

Post edited by: Pterosaur, at: 2007/04/14 14:55

What Ptero said was 100 percent correct but if you have an extra set of hands... pull on the thing while someone else taps it easily with a rubber hammer. The vibration from the tapping will allow it to slide over the shift shaft which is where it is hanging... the shift shaft on almost all bikes is bent some and like has been said, the seal is grabbing.

Careful not to apply force to the shift lever with the cover off, or you'll be replacing the seal.

If leaking you may want to replace anyway along with O ring on clutch pusher if it is leaking.

Thanks! Gave it a smack (oh about an hours worth) but couldn't get it off, will get after it in the am. May hook it up to the truck and give it a pull!