[winterstarranch]

I'm new to this posting business so I'm not sure about starting and finishing threads. I asked for help earlier in the week regarding a no spark problem, and received some helpful tips. I have ordered a pulse coil thinking that it may be my problem, and also a manual. Nothing has arrived so I am at a standstill until the manual and pulse coil arrive. I will report when I get the pulse coil installed and begin trouble shooting again. The problem that I have now is removal of the left side cover. after removal of the blots and drive shaft the cover appears to be hung up in the area of the shift lever. I cannot tell anything from the parts diagrams from the suppliers. Does anyone know if there is a circlip or e ring behind the seal on the shift shaft that prevents the side cover from coming off? Thanks.

 

[Helmut]

No, there isn't any type of clip that keeps it from coming off, it's probably just stuck on the shaft or trying to come off crooked. Did you remove the starter reduction gear under the black cover with the 5, 8mm bolts? If not, you need to remove that first.

BTW, make sure you don't let the shift shaft pull out any while trying to remove the cover. If you do, you will have to remove the right side cover and retime the clutch lever.

 

[winterstarranch]

Thanks I am puzzled perhaps it is just hung on the shift shaft I have double checked that all the bolts are out. I didn't think that there would be a bolt through from the other side. I didn't expect a circlip on the shift shaft as I could see no need for one but the side cover is loose all the way around except at that location. I did remove the starter reduction cover and pulled the gears. I thought that I would pull the side cover so that I could install the pulse coil when it arrives. I didn't want to get too aggressive but I have about an 1/8 inch separation down the case and had it separated with screwdrivers and was tapping the open end gently with a rubber mallet hoping to release the stuck end. Now that I know that there should be nothing holding it near the shift shaft I will get a little more assertive with it. Thanks.

 

[Helmut]

Just don't let the shift shaft pull out any while pulling on the cover or the right side cover will have to come off. There's a clutch lever that splines over the end of the shift shaft, behind the other side cover and it has to be timed. If the shift shaft pulls out any, the clutch lever will come off the end of the splines and be out of time when it goes back on. There's a punch mark on the clutch lever that has to be aligned with an index mark on the crankcase.

 

[shadetree]

take a large screw driver..wedge in between the opening of the shifter where it goes on the shaft..with a hammer....knock the screw driver down in between the slot..this will spread your shifting arm open enough to just pull it right off..then you cover will come right off...as helmut said..do not let the shifting shaft come out any at all..or you will have to pull the right side cover off in order to align it back up on the clutch side.

 

[winterstarranch]

Thanks everyone, I've got the shift lever off, I read a post earlier that said to use a longer, hardened bolt and nut when reinstalling the shifter and it reminded me that we used to do the same thing with the old tapped out junk that we used to ride. The case is hanging up near the shift lever I will probably work some more on removing it this weekend after I get my chores done. It may be that it is coming off crooked or that even though I've double checked there is still a bolt holding it. I'll let you know what I find out. WS

 

[shadetree]

Thanks everyone, I've got the shift lever off, I read a post earlier that said to use a longer, hardened bolt and nut when reinstalling the shifter and it reminded me that we used to do the same thing with the old tapped out junk that we used to ride. The case is hanging up near the shift lever I will probably work some more on removing it this weekend after I get my chores done. It may be that it is coming off crooked or that even though I've double checked there is still a bolt holding it. I'll let you know what I find out. WS

i posted something about using a grade 5 or 8 longer bolt and nut.when you put shifte lever back on...the oem ones are soft..and they tend to break off when you over tighten it..as for your case not comming of..the stator is probally holding it on..no other bolts hold it on once you take them out..well..shall i say none that is hiden..most times even if you think you got all the case bolts out..if it doesn't move any at all.there is always one bolt you missed !!!..been there soooo many times.

 

[Helmut]

If you're sure all the bolts are out, there's nothing else in there to hold it. Like Shadetree said, the stator might be sticking to the flywheel magnets, but it will pull on off.

 

[reuben_j_cogburn]

I posted on another section of this forum, concerning my own "no spark" issue with my 91'.
I'm going to keep my eye on this thread just in case. I'm hoping my problem is a bit less invasive! But the data is good to know.
In my quest to narrow my area of issues a friend, who owns a foreman 450, said his had a "rectifier box/voltage box, thatb went bad?. I don't even know if mine has one...
Anyhow.. If somebody could post a few pics of this particular operation, it would be interesting to follow, as i may be going down the same road myself!

regards...

reuben...