HEEELPPP ! urgent !

[bigredhead]

Ok.

i'm removing the left side case cover to replace the shifter pin and the gear shift pin..

I've been able to remove the starter cover and reduction gears, removed the foot peg, foot shifter, drained the oil, and removed all the bolts that hold the casae.

Now i have to remove the cover but it's stuck on there. I've got the heat on in the garage to warm things up. got a hair blower blowing hot air into the tranny and i don't dare try to split the cases with a flat head screwdriver....

HOW THE HELL DO YOU REMOVE/UNLODGE THE COVER !!!!

I have new gaskets to replace the ones on there if they get damaged.. but i canot remove the cover...

[MTS]

light taps with a screwdriver works good, just be extremly careful not to mar up the gasket surfaces, normally there is a little ridge ontop of the case that you can tap on from the other side of the motor to knock it loose

[mad_max]

This is on your SX right?

As I recall I had to unbolt the engine and lift it up a bit to get the cover off of mine. I think the lower part of the cover will hit the frame. As MTS says above dont mar or gouge the case.

[bigredhead]

yep the SX

I've found the 2 tabs that extent past the tranny case... and i've been tapping on them lightly. like said above i DONT want to crack that cover and it seems to be thin alum..

THe manual says it can be removed witht he engine in the frame.. goona be tight tho you're right !

So that's all there is to it ?

[mad_max]

Yep, just take your time.
Heres what it looks like when you take it off and remove the shift shaft

[Mr. Sandman]

Anytime you need to remove a head, cover, split a case, etc. use a plastic mallet or a with a block of hard wood, oak/maple etc. If all bolts and obstructions are removed and clear it'll come off but you might have to hit it pretty hard.

[bigredhead]

GOT IT !

I had to use a paint scraper with a rubber mallet and gently wedge it between the cases... and little by little i got it.

HOWEVER>. now like was said above, that cover will not clear the frame. i need an extra 1/8 .. even 1/16 more room.. i think i'm goint to have to loosen up the motor mounts to wiggle it outa there.

Having a hard time sliding the cover over the plines on the shifter too, but with frame clearance i think it will go.

[Wickedfinger]

I had to use a paint scraper with a rubber mallet and gently wedge it between the cases... and little by little i got it.

NEVER use anything like a flathead screwdriver or a chissle or a paint scraper to take any machined surfaced part apart. You would have been able to do it with a couple of whaps from a soft mallet. Consider yourself lucky if it dosent leak.

[short4stuff]

NEVER use anything like a flathead screwdriver or a chissle or a paint scraper to take any machined surfaced part apart. You would have been able to do it with a couple of whaps from a soft mallet. Consider yourself lucky if it dosent leak.

aslong as he didnt put any gouges or deep scratches in the metal. I think he will be ok.... I am sure he was careful when he was using it, and I am sure he knew what could happen .. thats why he didnt you a screwdriver.
Even if he did put a scratch on the gasket surface, alittle silicon would fix the problem.

[Wickedfinger]

aslong as he didnt put any gouges or deep scratches in the metal. I think he will be ok.... I am sure he was careful when he was using it, and I am sure he knew what could happen .. thats why he didnt you a screwdriver.
Even if he did put a scratch on the gasket surface, alittle silicon would fix the problem

. No, this is one case where you are ABSOLUTELY wrong and would never let you or anyone else let that bad information get into someones head. You do not "wedge" anything between machined surfaces, ever.

[bigredhead]

I was VERY careful using the putty knife, i got the cases mooving ever so slightly from using a rubber mallet and a socket extention by hitting the tab that extends from the cases.. one on the left and one on the right.. then with the putty knife i wiggle my way into the middle enough to get it done.

Then we had to remove the motor mounts to tilt the motor and remove the cover completely.

Found this :

[bigredhead]

1st picture, there is play in the wheel with arrows to it, should that be tight ? or does it have play ?

2nd shows the shifter pin with a 45 degree worn end.. don't seem bad tho.. but i had bought a new one, i put it in for the hell of it.

[mad_max]

1st picture, there is play in the wheel with arrows to it, should that be tight ? or does it have play ?

2nd shows the shifter pin with a 45 degree worn end.. don't seem bad tho.. but i had bought a new one, i put it in for the hell of it.

bigredhead, I never took that wheel part off my SX so I cant tell you for sure. The problem is usually either that the pin broke (the pin you have there with a worn end) or that the shift shaft has deformed, bent or broken. Heres what your shift shaft should look like (see pic) the green area is where they get messed up.

[bigredhead]

That part was fine on mine, no cracks, dents, chips, or serious wear. Thanks max !

Can anyone fill me in on that item i pictured tho ?

[Dirtcrasher]

That arm is the shift drum stopper arm. When you select a gear it sits in a detent or groove in the shift drum and that is what keeps the shift forks exactly where they need to be and the gears aligned. If there is play in the wheel then that will allow the drum to have play back and forth instead of being locked into the gear.

That shaft or stud is the one that the SX always has come loose, but if you loctite it and it breaks you will have a tough time getting it out. They are also hardened and thats why they snap and why it may also snap if you overtighten it. The stud returns the shift shaft to the rest position waiting to be shifted up or down again.

The 45 degree or bevel on the end of it has no affect on it's function, it's just a spring return shaft.

The SX being an automatic works great, but if you abuse it like powershifting or jamming it in gear with the power on you will beat it up pretty bad. I have seen lots of SX's with shifting problems.

My favorite is when people remove that right angle output shaft to get the motor out or the swingarm off and then when reinstalled they lose a thin thrust washer located past first gear into the cases. Even though it is possible to get that shaft out and back in through all the gears that washer slips down and many guys miss it. It may work for awhile but then you'll lose 1st gear and wear out the entire drum and a few other goodies. It is possible to get the thrust washer back in there correctly but most guys don't even know that it happened.

What was the reason you tore into this in the first place??