Stuck Clutch Cover

I need some help. I'm trying to get in to my clutch to fix a mysterious issue on my 82 GPz 750. For the life of me, I can't get the outer clutch cover off. All bolts are removed and I've been tapping on the thing with a small sledge cushioned by a small block of wood for about 15 minutes. My guess is that this thing has never come off before. That or the previous owner JB welded it back in place. Any suggestions?

- Jon

... I got it! Just took a couple more whaps.

Ok, next question. The old gasket is all deteriorated and stuck in bits around the cover and the engine case. How should I go about cleaning all that off?

Use a bigger hammer. :laugh: Sounds like it's on there pretty good. I'm guessing no leaks.

Try tapping a utility knife blade it and work it around...Russ

Got it! All it took was a beer break, a post to the forum, and a couple more whaps. Definitely won't be reusing that gasket. Good thing I have a new one.

Nope, there were no prior leaks. Actually, I'm pretty amazed at how leak free this bike is.

Try a broom handle through the oil fill hole and leverage it off.....

Ok, next question. The old gasket is all deteriorated and stuck in bits around the cover and the engine case. How should I go about cleaning all that off?

Loctite and Permatex make gasket removers. They dissolve the old gasket adhesive so you don't gouge the metal scraping off the old gasket. Use a cheap little plastic putty knife after the adhesive has softened.

Loctite

Permatex

650ed wrote:

Loctite and Permatex make gasket removers. They dissolve the old gasket adhesive so you don't gouge the metal scraping off the old gasket. Use a cheap little plastic putty knife after the adhesive has softened.

Loctite

Permatex

Nice. Thanks!

I have never attempted the gasket removers, so I am not sure if they will work on a DRY gasket. What I use is a single edge razor blade and a bit of elbow grease. You cant apply enough pressure to gouge the Aluminum and it will take about 10 minutes a side to clean.

I'm having the same stuck clutch cover problem. -Great timing otakar!- I've been using a rubber mallet to try to beat it off. :dry: I've even sprayed WD40 all around it hoping it would help but, no love.

What does the service manual mean when it says there are two 'knock pins'? If I try prying it with the broom handle idea, will I bend those pins?

Edit: I just got it! I tried the broomstick idea but it wouldn't budge a smidgen. I tried whacking it a few more times and the last time I hit it hard 'for good measure' and it popped off! Woot! Thanks for the ideas ya'll!

BTW, It looks brand new in there...the basket is all shiny and everything. Which probably means its not my clutch that is causing the jumping gear problem. But, I may as well check everything anyway.