I've had the cam cover (cylinder head cover) off a few times now and each time has brought me to pulling my hair out in frustration. First... to get it off it seems I have to remove the top breather cap because it won't fit through the frame with it on there.... which rips that gasket sometimes. Second... in order to remove the cam cover bolts, I have to move the wiring harness out of the way and remove the two ignition coils from the frame because I couldn't fit any kind of tool in there to unscrew them. Third... keeping the cam cover gasket on the cover while putting it back on always turns out to be an awkward frustration dance... since it keeps flopping out from one side or the other (which ever side I'm not on) There has to be a better way to do this so I thought I'd ask if you all have any tips. What tricks have you learned to do to make this a little less frustrating? Or should I just stop my whining and suck it up?
Also, while I was taking the carbs off for another matter, the manual said to take notice of where the carburetor overflow tubes are routed. I don't have carburetor overflow tubes... but there are ports on each carb where I think they should go. I thought maybe I am mistaken and the overflow tubes are something else. Does anyone have a photo of the overflow tubes from the carbs?
Quote from: Erika on January 20, 2014, 07:00:50 PM
First... to get it off it seems I have to remove the top breather cap because it won't fit through the frame with it on there.... which rips that gasket sometimes.
Yep. Never had a problem with the gasket though. Maybe soak it in oil before putting it on to try and stop sticking?
Quote
Second... in order to remove the cam cover bolts, I have to move the wiring harness out of the way and remove the two ignition coils from the frame because I couldn't fit any kind of tool in there to unscrew them.
Right angle hex keys are your friend.
QuoteThird... keeping the cam cover gasket on the cover while putting it back on always turns out to be an awkward frustration dance... since it keeps flopping out from one side or the other (which ever side I'm not on) There has to be a better way to do this so I thought I'd ask if you all have any tips.
Silicon gasket maker/sealant between the gasket and cover keeps it stuck in place well.
Long ball end allen wrenches - even the socket type - make getting the bolts out real easy.
+1 on the sealant. Smear a little of that read gasket stuff on to hold it in place.
OR put the gasket down first. Then lay the cover on and poke the gasket into place.
With a little practice it gets easier.
We always disconnect the choke cable. Makes it easier.
Breather gasket:
When you assemble it put a smear of RTV sealant on one side of the gasket and a smear of grease on the other side. That way the gasket will stay on the sealant-ed part next time you disassemble.
Cover gasket:
It's a labrynth seal so should not need sealant if it's in good nick. Just put a few light dabs of RTV at a few places around the groove in the cover, press the rubber seal in to the groove. The sealant will hold it in place for assembly, but won't cause hassles next time you want to (say) replace the rubber seal.
IMHO.
Yes the breather box needs to come off.
I always use a very sticky gasket goo on the gasget which has the handy side effect of keeping it in place (mostly)
About the main bolts- they are allen key heads right? A normal allen key should do it easily.Sorry i cant remember excat details from the last time i did it-just that it was a bit fiddly.
is there a back and front to the cam cover? have mine off at the minute and it seems like it will go on either way, is this true? cheers;T
Yes there is a front and a rear, ask me how I know this. The front and rear mounting holes on either side of the cam chain only bolt in one way. Look for the mounting hole on the motor between the carbs
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Also the front and rear bits are different lengths.
Remember the gasket also has a front and rear. If it doesn't fit it is not because it is a cheap chinese one - it is because you have it backwards.
Cool... I will definitely try some of these tips. I'm glad I don't need to put sealant on both sides... that's a pain when it sticks to both surfaces. It's also a real scream when the gasket arrives in the mail all crumpled and kinked making it not want to stay put. I couldn't fit a ratchet with alan attachment and the right angle alan wrench started to strip the bolt so I took the coils off to get more torque. But a longer ball alan wrench looks like it could be the ticket... I didn't know those existed.
Thanks!
If its starting to round now, replace it! Since I started working on bikes I found that my Allen key collection has grown 10x, mostly 5-10MM haha
Taking the valve cover off - I like ball tip allen sockets and a handle spinner - one of those wrenches where you spin the handle of the ratchet and the head spins.
The long handle allens tear up the frame if you're not careful especially as the wrenches get use and sharp spots in a few attempts of removing stuff.
The gasket - you can clean the valve cover and use rubber cement to glue the gasket to it.
The throttle and choke cables get in the way, but I usually yank off the choke cable off the carb cos its easy to hook up when done. I leave the throttle cable on but pull it and sit it near the right side frame and make room for the valve cover.
Cool.
Buddha.