Has anybody here cut down their cam and sprocket cover? Looking for pictures and any advise on how you did it.

Thanks,
Joe

 

I used a saws-all to make the first cuts because it was fast. I was careful to leave about 1/2 inch or so out side the gasket surface.

Next came the grinder to get me within 1/4 to 1/8 inch...

Then the dremel with assorted stones and sanding roles to get me flush up to the gasket surface.

Last was the hand file and sand paper to get everything smooth and even.

 

One last note...

If you've never taken a saws-all to a perfectly good motorcycle you're missing out. Try it sometime.

 

Found another pic post chop, pre-paint...

 

Looks good. I was wishing for access to a metal band saw but a saws-all could be an option. Thanks for the pics.

 

If you have an angle grinder with a cutoff wheel and 80 grit flapper disk
then you're set... or if you have a hacksaw and a file... it'll just take more
than an hour.

Angle grinder is the easiest, cut and leave 1/4" extra then put an 80 grit
flapper wheel on the grinder to smooth it out. Then hand wet sand it starting
with 120 grit. If you have no ambition then spray paint and be done with it...
if you want to be a king, then hand sand up to 600 or 1000 grit then buff it on
your bench grinder with spiral sewn wheels black emery grit compound first
then white polishing compound.

Oh and please loosen your push rods so you don't take any chances hurting
your cam bearings.

Chop scrap from the captains seat...



Heading for the garbage...




Flapper disk - flapper disk - flapper disk ...



Hole in the center of the bottom that needs plugging on '98 or earlier (none
after about '98), hole on the right is for ignition wires... please deburr it...



Yuck still looks like crapola...



Sand... Sand more.... not done yet... sand more....

Ding - Time to polish....









And don't neglect your sprocket cover...



Gazza