replacing gearcase cover help

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Jan 18, 2006 | 05:53 PM

JKDJose

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replacing gearcase cover help

I am trying to replace the gearcase cover on my 91 sportie and I am having trouble. I am replacing the cover because the timing standoffs that hold the timing cover on were completely rotted away and snapped off, so I am trying to repair it.

Beside removing the screws that hold the gearcase cover on, is there anything else I have to do to remove it?

I noticed that there's a sensor that is attached to the timing cup that rotates.

I tried removing it today but it feels like it's getting caught on a stop or something.

Please help.

Jan 18, 2006 | 08:35 PM

Wolhar

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RE: replacing gearcase cover help

From your description you are trying to remove the Primary Cover (left side sitting on bike) if that is correct, you must remove Derby cover and disconnect clutch cable, and you have to loosen primary chain adjuster and let all the tension off the primary chain. on a '91 model you may have a worn shoe on the primary chain adjuster that is "holding" it to the chain so to speak, do not continue with this project unil you PM TCSTD or pococj on this site. Also check th DIY page.

Jan 18, 2006 | 08:39 PM

pococj

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RE: replacing gearcase cover help

Rusty, he's talking about the cam cover. I've never had a late model Evo Sporty apart, so I ain't gonna be much help. I will submit that if you're gonna go that far into the thing, you need a service manual, like yesterday!

Jan 18, 2006 | 08:41 PM

JKDJose

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RE: replacing gearcase cover help

I have the both the clymers and haynes and all they say is to remove the bolts and take the cover off which is not happening. I need to know if the manual is missing something else.

Thanks.

Jan 18, 2006 | 08:54 PM

Wolhar

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RE: replacing gearcase cover help

Wrong, dude this is a major piece of work. those manualas are missing a bunch.

Quote:

ORIGINAL: JKDJose

I have the both the clymers and haynes and all they say is to remove the bolts and take the cover off which is not happening. I need to know if the manual is missing something else.

Thanks.

Jan 18, 2006 | 08:55 PM

pococj

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RE: replacing gearcase cover help

Go to the ignition section of the manual. I have an old 1979 Sporty manual that tells how to remove the ignition stuff, but it is only in the ignition section and not in the section that covers removing the gearcase. That stuff has to come out before the cam cover can come off.

Jan 18, 2006 | 08:59 PM

JKDJose

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RE: replacing gearcase cover help

Thanks Pococj. I found it. I have to remove the ignition sensor and then the bolt behind it. It was in the clymer's I just needed some motivation to keep looking. Thanks a bunch.