Clutch Cover Removal - Won't budge!

stephan · April 01, 2006, 12:33:36 PM

During the end of last years riding season I noticed my GS develop a leak coming from the top right clutch cover area. "No problem" I thought, I'll just replace the clutch cover gasket when things warm up a bit. Well here I am trying to do a simple job that is now going into 2 hours of gettin' nowhere fast.

I removed the pulse/voltage generator from the end of the crank and also removed the thirteen bolts around the edge of the clutch cover. I tried to pull it with my hands, nothin'. I tried to hit it with my palms trying to jar it loose, nothin'. Okay, no problem, I've got hammers. So I tried my regular 20oz. hammer with a shop rag so I didn't beat my case to death. I then tried a 16oz. rubber mallet. Then I tried setting the mallet on the case and hitting it with the regular hammer - nope. I've pried on the little pry tabs but I'm worried about snapping them off. I have the left side at least moving about 1-2mm away from the engine case. The right side is welded on I think.

Has anyone ever ran into this? What did you do to get it loose - help! I just want my bike to be fixed so I can use it. I lost my whole last summer to this cranky machine and don't want to loose this one.

Thanks!

sledge · April 01, 2006, 12:53:15 PM

If my memory serves me right there are more bolts under the plate the ignition pick-up fixes to that have to be removed. I think they are a 7 or 8 mm head. Someone with the Haynes or Clymer manual will be able to confirm this.

MarkusN · April 01, 2006, 01:46:23 PM

Did you just remove the ignition rotor, or the stator as well? According to the Suzuki manual the stator has to go.

speedyts49 · April 01, 2006, 01:52:05 PM

http://gstwins.com/gsboard/index.php?topic=23879.msg244760#msg244760
I did mine recently, here's the thread.

There are a couple of screws inside the Suzuki cover #13 on the schematic that need to be removed as well.

stephan · April 02, 2006, 01:20:29 PM

Well I'm a dork. Turns out you have to actually take out ALL the bolts to remove that cover. I missed the two bolts under the ignition rotor. I really don't remember the Clymer manual mentioning those but it doesn't really matter 'cause no matter they have to be removed to get the cover off. Once I took those bolts out the cover pretty much fell off. Getting the old gasket off was a pain, but I used a wire brush, carb/choke cleaner, fine sandpaper and a razor blade. Took some work but got it nice and clean.

Thanks for the replies - I feel silly. At least I'm a happy dork because my bike is ready to roll! At least I can be happy that I didn't break anything in the process because I was really cranking on those pry tabs - oops!

MarkusN · April 02, 2006, 02:07:21 PM

Warning! When you put on the new gasket make sure that the oil channel for the balancer shaft bearing does not get obstructed. Aparently that's very easy to do.

Wouldn't be the first Engine to blow that way.

stephan · April 02, 2006, 05:57:39 PM

I know what your talking about. I made sure I cleaned the channel on the cover very well. The channel on the engine case was clean and clear. No gasket material stuck to that, it only stuck on the cover. Thanks for the warning though, it would be a bummer if a cheap gasket ruined my bike for good - doh!!!

pbarnello · May 13, 2006, 02:08:03 PM

I realize this is an old post but how did you remove the pulse/voltage generator?
did you use a puller? was it easy or hard?
any help would bew greatly appreciated
-Pete

speedyts49 · May 13, 2006, 02:23:51 PM

Quote from: pbarnello on May 13, 2006, 02:08:03 PM
I realize this is an old post but how did you remove the pulse/voltage generator?
did you use a puller? was it easy or hard?
any help would bew greatly appreciated
-Pete

There is a 10mm bolt for the signal generator and a couple of screws i believe that hold the stator plate and there is a wire that needs removed also. No puller is required.

PatrickInNC · April 22, 2007, 11:51:33 PM

Hey guys,

I am having the same issue. Here is a pic of where I am at. Is there something else I need to take off. And by the way. The Clymer manual does not say how many or which bolts need to be removed to get the cover off.

So any suggestions? I've been wailing (notice the marks around the top left) with a rubber mallet. I seem to remeber that the other side was pretty hard to get off too. I think it is the original gaskets, and they are extra hard to get off, at least the left side was.

soooo.. suggestions??

dgyver · April 23, 2007, 05:37:35 AM

It is just stuck with gasket. There are a couple of pry tabs. You can see the rear tab if you follow the 2 wires at about 8:00. I believe there is anoth on the front side.

PatrickInNC · April 23, 2007, 07:49:21 AM

Thanks I will try that out.

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Clutch Cover Removal - Won't budge!