kz1000 - removing stuck alternator cover - hint ?

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20 Feb 2022 21:04 #862659 by KZmarcel
Howdy all.
Painted my engine today, now wanting to remove engine covers for polishing. 
That alternator cover is quite stuck on.
Starting to look like "an electrical problem". Joke aside, I tapped it with a rubber mallet, I tried my trusted piece of 2x4 coming from behind and under and hammering at the one (top right) place where my 2x4 could catch. No moving.
Any hint ?

WA state, USA
1981 KZ1000 Ltd project for me
kzrider.com/forum/11-projects/617085-kz1000-full-spa#861637
1982 KZ440 Ltd project for my wife
1991 Yamaha 1200 VMax
2005 Kawasaki Vulcan 2000
1971 Buick Riviera boat-tail
2004 Jaguar XJR
1999 Dodge Ram 5.7L Magnum
1977 John Deere 400

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21 Feb 2022 01:05 - 21 Feb 2022 01:06 #862664 by 750 R1
Maybe try heating it up with something like a hair dryer, or heat gun, be a bit more careful with a heat gun, then tap it with a rubber hammer...

If that doesn't work it may just be an electrical problem !
Last edit: 21 Feb 2022 01:06 by 750 R1.
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21 Feb 2022 01:13 #862665 by zed1015
It's a combination of the old gasket, Rotor magnetism and the two location dowels holding it on.
A bit more work with the mallet and a carefully placed flat bladed screwdriver top and bottom at the dowel locations once you have a small gap is the way to shift it.

 

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21 Feb 2022 02:20 #862666 by woodyvale
Had the same on my gpz. the location dowels were gummed up and stuck plus the rotor magnets make it harder to pull off.
More tapping is needed. Once you see a small gap you know its moving.
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21 Feb 2022 19:27 #862711 by KZmarcel

Had the same on my gpz. the location dowels were gummed up and stuck plus the rotor magnets make it harder to pull off.
More tapping is needed. Once you see a small gap you know its moving.
Thanks all.
Indeed I went with a painter tool (the thin scraping weirdly-shaped thing) in the gasket area here and there, then inserted flat screwdrivers and gently pried and "voila !".
Same deal with the clutch cover.
Starting a separate thread with questions regarding what I found behind the covers...
 

WA state, USA
1981 KZ1000 Ltd project for me
kzrider.com/forum/11-projects/617085-kz1000-full-spa#861637
1982 KZ440 Ltd project for my wife
1991 Yamaha 1200 VMax
2005 Kawasaki Vulcan 2000
1971 Buick Riviera boat-tail
2004 Jaguar XJR
1999 Dodge Ram 5.7L Magnum
1977 John Deere 400

Please Log in or Create an account to join the conversation.

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