Hi guys. Trying to remove the gearcase cover on my '75 XLCH. Below is the picture. Been following my service manual.



The pushrod is out and all the bolts are off. I've disconnected the line above the shifter. I've been tapping it gently and it loosens. Not sure if I should continue to tap it or if I am missing something?

 

Are all of the pushrods completely out? It does not appear that way in the pic. They all must be completely out. I presume the generator is also completely out as it also must be.

The shaft at the bottom left of the pic is for the crossover linkage, which i am not familiar with. However, on my 1978 that shaft is part of the rear brake linkage, and if the linkage is not loosened off that shaft is jammed in the bushing.

OK i just looked at the pic again - you have to uninstall the ignition components behind the 3" diameter cover in the middle of the gearcase [cam] cover. Remove the cover. It is probably points in there. Mark where the backing plate is positioned as it must be re-installed precisely precisely precisely where it is now.

After you re-install you should re-set the ignition timing. I'll post a link to a very good YouTube video for this ...

 

have you taken all 4 out?

 

http://www.youtube.com/watch?v=mKVh4pbyh2A

 

if you remove the lifters and blocks, you can use a small screwdriver to gently push the cams back into the bearings as you work the cover off. this will allow you to see how they are sitting and lined up (and prevents them from all falling out onto the floor). Take a pic of this so you have it for reference when you want to put it back together. If you time the motor before starting you will see the marks all lined up (you hope) when the cover comes off.

 

Hey guys, sorry to resurrect this thread. Thanks for the tips. I WAS doing this wrong. I have not taken the cover off, but when I was tapping the cover with bolts out and pushrods in, do you think this caused any damage? I was using a rubber mallet but not whaling too hard. Would everything be OK?

Thanks.

 

The possible sources of damage are ...
1. the soft brass bushings in the gearcase cover itself can be damaged by angular contact with the steel cam shafts
2. the cover can be weakened or cracked at some points

It is unlikely that either of these has occurred.

If you need/want the cover off simply remove the pushrods and carry on. A good place to tap [gently] is thru the generator hole. I use an ~6", 1X2 wood block and a regular steel hammer.

If you see anything of concern posts pics. Best to use a tripod/steadying device and no flash, as the light from flash hides details.