Re: Generator inspection cover

benny hedges · Post by **benny hedges** » Wed Feb 09, 2011 6:04 pm

boiling water over it first.

Wicky · Post by **Wicky** » Wed Feb 09, 2011 6:06 pm

drift the cap off carefully with an old screwdriver (or punch/chisel) in the undo direction at a very shallow angle.

http://www.google.co.uk/products/catalo ... ps-sellers

http://www.ronayers.com/Fiche/TypeID/26 ... ALTERNATOR

Put the part no. in here

http://www.davidsilverspares.co.uk/part ... rt-number/

order and pay - wait for postman

tony.mon · Post by **tony.mon** » Wed Feb 09, 2011 8:48 pm

Here's how I removed one:
just be careful how you hit it when trying to use a drift.

If you tap four small centre punch marks in, and then place the punch at a 45 degree angle to the casing, drifting the cap in the "undoing" direction it should come loose after a few taps.

Hit it about 5mm in from the outside edge, because the part that carries the thread and extends into the opening is under this; you're less likely to snap off unsupported areas.

Don't hit it too hard because you can punch a hole in the generator casing!
But if you do I have spares.

tony.mon · Post by **tony.mon** » Wed Feb 09, 2011 9:21 pm

Centre punch will be fine.

AMCQ46 · Post by **AMCQ46** » Wed Feb 09, 2011 9:29 pm

KneeWobblers wrote:I have today attempted to "tease" the inspection cover off (30mm one) and whilst "teasing" I made a right horlicks of the gruyere type metal used to to make this thing. well it now looks like a wounded Iraqi and it aint going anywhere. Advice please.

good to see you are getting this out of the way before you bring the bike to me.........I will keep the hamers hidden till we do the valve checks

Wicky · Post by **Wicky** » Wed Feb 09, 2011 9:30 pm

tony.mon · Post by **tony.mon** » Wed Feb 09, 2011 9:35 pm

If you get truly stuck on the workshop day you can just remove the smaller inspection cap and rotate the engine on a paddock stand by rotating the rear wheel in gear.

AMCQ46 · Post by **AMCQ46** » Wed Feb 09, 2011 9:43 pm

bennys suggestion of boiling water is a good option, as differential thermal expansion is a great thing for freeing things off. and impacts are always better than gentle force to get things moving.

Hit the F**king thing a right good tw*t with a big hammer

benny hedges · Post by **benny hedges** » Wed Feb 09, 2011 10:21 pm

AMCQ46 wrote:bennys suggestion of boiling water is a good option, as differential thermal expansion is a great thing for freeing things off. and impacts are always better than gentle force to get things moving.

Hit the F**king thing a right good tw*t with a big hammer

be carefull with that though as the casing is very thin where it turns in around the thread... i realised that when i broke mine, it's like 2mm thick around the edge where the thread is and will break easy if you hit it too hard, then you not only need a plug but a casing as well

Wicky · Post by **Wicky** » Wed Feb 09, 2011 10:25 pm

and when finesse is required - bring out the plasma torch...

http://www.muwhahaha.com/

benny hedges · Post by **benny hedges** » Wed Feb 09, 2011 10:26 pm

or the sonic screwdriver...

Wicky · Post by **Wicky** » Wed Feb 09, 2011 10:38 pm

155-millimeter nuclear shell should easily resolve 30mm cover problem

tony.mon · Post by **tony.mon** » Wed Feb 09, 2011 10:50 pm

It can be done.

It may not be pretty, though......

benny hedges · Post by **benny hedges** » Wed Feb 09, 2011 11:55 pm

another ugly way of getting it off is to remove the cover completely, drill through the 10mm allen socket hole and fit a bolt & locknut through it.
tighten it up and use it to undo the cap.
if you want to still use the same cap you can trim the bolt down so its not so ugly but it has to be a oiltight seal.

best bet is get it out and order a new one. grease the thread though like it says in the good book, and dont tighten it too tight.

benny hedges · Post by **benny hedges** » Sun Feb 13, 2011 12:54 pm

respect!