How to remove R/hand side outer cover.

Billiam · Post by **Billiam** » Tue Sep 06, 2016 3:37 am

Kick start works OK but there is a lot of play on the shaft so attempting to get at it to see what can be done. A new bearing maybe
I've removed all the Phillips screws, the two circlips and the rubber bung.
Is there anything else holding the cover on, i.e the hex bolt in the middle, before I get serious with the mallet.
Ithangyou.

Seadog · Post by **Seadog** » Tue Sep 06, 2016 6:43 am

You didn't need to remove the clips or the plug. Leave the center bolt alone, it's for clutch adjustment. The kick start lever is on a splined shaft, so the cover needs to pull straight out, not up. You'll need to take the muffler off. You should not need a mallet.

Look at the parts diagram. Do a search on this site for proper installation instructions. You'll have to align parts before the cover goes back on.

Yedar · Post by **Yedar** » Tue Sep 06, 2016 10:04 am

My RH cover removal method is :-
1-Remove the brake pedal/R footpeg & move to one side
2-Remove RH silencer
3-Remove the alternator cover
4-Remove drive chain top cover (2 screws)
5-Having removed the 6 cover screws it is not necessary
to remove anything else at this stage, hold the kick lever
& move it clockwise a couple of degrees this removes the lever
return spring tension from the intermediate gear splines as
the cover is pulled off - it should require no force
Gently release the kick lever spring tension then disconnect the clutch cable,
it is now ready to play with.

Take notes/photographs to aid re assembly of the kick gears, they
have "0" & "."marks on them. The lever pinch gap should line up with
a dot on the splined shaft.

The lever bush is probably shot.
Bush size (mine) is 25mm OD X 17mm ID X 32mm long with a 5.5mm hole
6.5mm from one end to line with the grease fitting.
Hope this helps.

Billiam · Post by **Billiam** » Tue Sep 06, 2016 12:03 pm

It certainly does Yedar. Thanks. Just the info I was after.
I'll pop the circlips back on and start turning the bush up on the Lathe. (Southbend Indiana !)
The bike has stood for many years untouched and the cover faces have bonded. So some light persuasion is going to be required methinks.
Thanks again.
Billiam
May the force be with you.