Clutch cover removal

[Davelu88]

Hi All , after alot of swearing and threatening to scrap the bike the engine has finally let me get out all the screws holding the clutch cover on , however it does not want to let go of the cover so easily,  anybody got any tips to get it off as I think this maybe the first time it has been apart .
Thanks Dave

[Oddjob]

There are 2 dowels holding the casing to the crankcase. They have most likely rusted a bit and bonded into the case.

Rubber hammer and some heavy hitting usually does the trick. You could also try pulling the clutch in as the action should force the cover away from the crankcase. Don't try and lever it off.

Just bought a pile of parts for the 550 just yesterday, there are around 5 clutches in the job lot so if you ruin the casing I can let you have a spare cover dirt cheap.

[Davelu88]

Many thanks Oddjob, 😊

[Oddjob]

Try the clutch action first, it often works. If not try holding the clutch in whilst hitting the case with a rubber mallet. A compethane hammer is best, a dead blow one with lead shot inside.

[Davelu88]

Got cover off with rubber mallet , but this washer fell out ? Looked at schematics but still not sure as don't  seem to fit anywhere.

[Trigger]

It goes on the kick start shaft so, the shaft doesn't wear the case   

[Davelu88]

Many thanks Trigger 😊

[JezzaPeach]

Just a suggestion (you may well already do!) from when I did mine (excellent 500 push rod supplied by Trigger!) I used a fine wood chisel (and heat as suggested by Julie) to scrape the old gasket off. I found the chisel more controllable that eg a craft blade which tended to skid or dig in.

[Davelu88]

Thanks Jezza , I will have a go at that as gasket stuck on firm in parts