I'm trying to replace the pan gasket and the clutch side cover gasket. I double and triple checked, and yes, i have all the bolts out. I have tapped with a hammer. Still no budging. What is the deal?  When you guys remove yours the pan just falls down once all bolts are out? Help is appreciated. Thanks

Patrick

While waiting I unbuttoned the clutch side cover, and having the same problem there. I got all the bolts off including the ones under the sprocket cover. I don't want to damage the aluminum but it feels like i'm going to have to forcefully pry. Any help?

-Patrick

The clutch cover has a tab at the lower front and a tab at the rear for pry points.  Just don't over-do-it; they are not idiot proof.

The oil pan I would  forcefully bap with a rubber mallet.  Or horizontally with a wooden drift.  I just wouldn't pry between the gasket surfaces since AL is soft and it would tend to defeat the purpose of sealing leaks.          

Is that the left side cover(alternator-sprocket cover is behind it) or right side cover(clutch side)? If its the left side cover the stator magnets will be trying to hold it on. You can grab it with your hand s and wiggle it. Once it's started it will come loose. Be careful with the stator wire as it's not too long.
Not sure about the clutch side cover as I haven't done it yet. There may be some bolts under the pulse generator you'd have to remove.

Hi there,
Yes, a large rubber mallet is what you need to unseat them. A plastic mallet would work, too.
It needs to be a several pound rubber mallet though, a small one won't work.
Whatever you do, DON'T try to stick a screwdriver or chisel or anything pointy into the gap between the mating surfaces. You will damage the surfaces and cause leakage.
Patience and the proper mallets are what you need.
Tapping with wood and hitting the wood lightly with a regular hammer would be fine, but be gentle.
The advice about the magnets and alternator are correct. You will feel that resistance from the magnetic bond once you loosen the cover.
Best of luck,
Todd

Thanks all! I was getting frustrated last night. I will go swing by somewhere and pick up some plastic and rubber hammers. I am taking off the left side cover the one with the stator underneath. I didn't think about the magnetic pull. So the side cover has 2 pull points? Ok I'll look for them. We'll see and I will be a happier person once the GS doesn't put oil on the ground.

Update later and if this works i really appreciate it.

Patrick

Done for the most part. I can't believe those gaskets were so good at adhering to the metal and so bad at actually doing their job. I spent a majority of the day scraping. And nothing I tried, not paint stripper lacquer thinnner carb cleaner, nothing would break them down to make it easier. Oh well. I gotta replace a bolt that was broken on the side cover, and I stripped a nut and maybe one of the screws on the oil filter cover, so we'll see how that works out tomorrow. Unfortunately no riding for me tomorrow, and that will mark the first day I haven't ridden to school since last fall. Bummer. Oh well Thanks for the help.

Patrick

Get some of this, it will have those old gaskets off in minutes. It sprays on like shaving foam and within minutes the old gasket has softened enough to just scrape it off without effort or damage to the mating face.  Good motor parts dealers will stock it.

http://68.72.74.113/PRODUCTS/790.htm