What's the trick (Chaincase cover removal)

NY AttakGT

NY AttakGT

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Trying to get Chaincase cover off in '07 Attak, which I have had off before. I have removed 6 bolts (two 14mm, three 12mm, and one 10mm from center of cover). Doesnt want to budge. I think it is getting hung up on the reverse forks. Put all the reverse linkage back together and was shifting back and forth reverese to drive a few times, thinking it would release whatever was caught up. Spraye the top bearing down with rust penetrant (thinking it might be getting caught on the top cover bearing, no good.

How much throw should the reverse mechanism have where it goes onto the cover? It doesnt seem to move very much. When disconnected from the linkage, should I not be able to pull it straight up, disengaging the fork from the backside of the lower gear?

Just feel like I am missing something....a crucial step or bolt or something.. Does the bearing behind the speedo HAVE TO be removed first possibly?
 
Did you loosen the set screw on the lock collar on the jack shaft? Its behind the brake rotor.
 
Mine did the same thing just took some grunting and trying to keep the cover sliding off perfectly straight on the jackshaft.

Watch the coolant hose off the radiator the reverse linkage kept getting caught on that when I was trying to pull it straight off.
 
This might be of some help?
http://www.ty4stroke.com/viewtopic.php? ... highlight=

I plan on doing mine soon as well but I curious to hear what you find out is going on with yours?

The reason I want to check mine is I believe it has never been apart, only 2,100 miles so I want to get in there to check and clean everything up.
Also, on the tensioner, being finger tight can also mean being to tight as some are stronger than others so I want to make sure I have the correct tension.

With reverse on these sleds, is the same true, a reverse equipped sled should run the chain slightly looser compared with a non-reversed model?
 
Popped off the speedo bearing..still no luck! My thinking is it HAS TO be the linkage fork is getting caught up on the gear inside the case. I dont seem to have alot of movement on reverse mechanism going into the cover. With all the linkage off, should I not be able to swiwel the mechanism up (counter-clockwise) so the fork is clearing the gear?

E-Brake removed
Circlip and spacers removed
Brake caliper and rotor removed
Brake rotor removed
Collar behind brake rotor removed (with t-20 set screw).
6 cover bolts removed (2-14mm, 3-12mm, 1-10mm)
Speedo bearing removed

Am I missing something?
 

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it is not the reverse fork. that fork would not move at all if it were frozen enough to prevent the case cover from moving. you said that you have some movement with it. Kinger is right, the cover is hung up on the jackshaft bearing. Mine was an absolute bear to remove, but I knew it was safe to pull because it mover the first few centimeters before it hung up on the bearing. if it had hung up before any movement, I would have been reluctant to continue oulling. Basically, I wiggled the cover to and fro repeatably (small movements) while pulling. kinds like "walking" it off. BTW, thare is no way to use any kind of bearing puller as the case it asymetrical. Good Luck
 
Man..this thing is being a real bear!

Something is still telling me it is getting caught up down low. How much movement should i be getting between reverse and drive (at the mechanism sticking out of the left bottom of the chaincase? I am am only seeing 3 degrees or so of movement. And I cannot whatsoever move it by hand. I have to hook up the linkages and lever to be able to move it at all. Shouldnt I be able to at least wiggle the mechanism by hand?

I'll just keep on reading and keep on trying.
 
Steve, Like the previous post said. Just whack the chain case all over with a rubber mallet, and it should loosen it up. Maybe you bent something doing those jumps in thr field off the canal trail by Booneville last year. LOL. I just had mine off a couple days ago to swap out my studded track and put an ice ripper in before I put another stud through the heat exchanger. My chaincase cover was a little tempermental, but nothing a couple good whacks with my mallet couldn't overcome.
 
tstewartfn14 said:
I had the same issue. The two set /guide pins had some oxidation which made it difficult to get started. Rubber mallet and some swearing and it finally gave in! :o|
Click to expand...

BIG BLACK WARRIOR said:
Steve, Like the previous post said. Just whack the chain case all over with a rubber mallet, and it should loosen it up. Maybe you bent something doing those jumps in thr field off the canal trail by Booneville last year. LOL. I just had mine off a couple days ago to swap out my studded track and put an ice ripper in before I put another stud through the heat exchanger. My chaincase cover was a little tempermental, but nothing a couple good whacks with my mallet couldn't overcome.
Click to expand...

Ehh, I been beating the snot out of it with the rubber mallet! Wiggling it, jiggling it, caressing it, yanking it. Got to be...... something.

Gonna have at it again in a bit after I put the kids to bed. Just really taking it apart to check all the bearings and inspect everything is good inside the case. I think it is gonna be one of the cases where I I pulling and next thing I know it is off and in my hands. Just wanted to make sure I was not overlooking any disassembly steps.

In the meantime, keep the suggestions coming!
 
I usually try a little wine, some candlelight, smooth jazz and sweet nothings whispered.


OH!!!!! You're talking about sled problems.... Just whack it good with a hammer, works everytime!
 
If you have the lock collars all removed and all the bolts it should come right off. It does not always slide off easy, you might have to spray the shaft with some lube or even lightly sand the shaft down to get any rust or frozen debris off.Try spraying it then sand the entire shaft on the outside of the chaincase cover and then spray it all down clean with a rag and give a good tug,one hand on top and bottom try not to cock it as you pull. I have removed many times,sometimes it comes off easy sometimes hard, I had to sand and clean shaft on time I remember that I had trouble. Its getting the reverse linkage back on the reverse gear you have to worry about.
 
Got it! The guidepin on the way bottom left of the cover must have had some corrosion and was sticking. I was noticicing the case was not splitting down low, hence why I thought it was the fork getting stuck on the gear. Being the bottom was sticking, the cover would not come off, since it has to come off evenly.

Took a small flathead and tapped it lightly into the groove (between cover and case) on the bottom left of the cover, going on the extreme outside near the bolt hole so the mating surfaces or gasket did not get damaged). Got it seperated a little and sprayed some penetrant in the 12mm bolt hole above the guidepin (so it could seep down)and let it set for a few minutes. Viola, went back at it, wiggle wiggle, jiggle jiggle....cover was in my hand.

Thanks for the tips.

PS. Boomer, I had the Barry White cranking and a bottle of Chardonnay sitting on top of the gas tank. Sled wasnt hearing it. Needed to man-handled it and pryed her open!!
 
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