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How to remove crankcase cover

Discussion in 'XJ Technical Chat' started by elliott, Apr 22, 2016.

  1. elliott

    elliott Member

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    Hey guys,

    I'm attempting to rebuild my 85 XJ700 clutch with brand new parts from xj4ever. I read through the guide at http://xjbikes.com/forums/threads/clutches-101-part-1-the-400-550-600s-with-pics.29541/ but I somehow can't even get the crankcase cover off. I detached the clutch cable from the pivot shaft throw arm and removed all the crankcase cover bolts using a 5mm Allen wrench. Somehow the crankcase cover is still solidly connected. Is it the gasket seal that's just holding it in place? Do I have to remove the pivot arm completely before the cover can be removed?
     

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    elliott, Apr 22, 2016
    #1
  2. jayrodoh

    jayrodoh YimYam

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    After 30 years, the gasket gets baked on and the dowels get attached to their home. They can be tough to pull. Pry carefully (not on the gasket surface) and some smart blows from a rubber or deadblow mallet will get her moving.
     
    jayrodoh, Apr 22, 2016
    #2
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  3. lostboy

    lostboy Well-Known Member

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    Start with a thin steal putty knife with the sharp edges filed off. Work your way around the cover. Then when a gap shows up then start to use wooden wedges.
     
    lostboy, Apr 22, 2016
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  4. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Just tell it to stay on so you can get the bolts back in. It will immediately fall off just to spite you.
     
    k-moe, Apr 22, 2016
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    PilotSmack, jayrodoh and XJ550H like this.
  5. elliott

    elliott Member

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    Hah! Yeah I ended up just holding a piece of wood to it and firmly smacking the wood with a mallet. Then it pulled right off.
     
    elliott, Apr 23, 2016
    #5
  6. lostboy

    lostboy Well-Known Member

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    Makes you wanna do the happy dance!
     
    lostboy, Apr 23, 2016
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