Puzzle - How to Remove Intake Valve Cover

[schrader7032]

Bike is a R25/2. I've looked at this a while and can't see a way around this. I
had to loosen the solo seat spring so that the rear of the tank could clear the front of the
solo seat. I've got the exhaust (FWD) valve cover off but the intake valve
cover is captive. I can't get it high enough to clear the rocker arm towers and
bolts. It won't go forward because of the valve cover stud for the cover
locking bolt/clamp. It won't spin around any. Of course the frame tube is
blocking it as well.

What's the second code word?? Do I have to lower the engine in the frame?

[c.d.iesel]

.....must of been a design improvement on the R27 ?

both of my covers rotate, angle, and slip out from under the tank without
loosening anything

a possibility is the center stud is sittiing too high
for the cover to rotate and slip by ??

[schrader7032]

a possibility is the center stud is sittiing too high for the cover to rotate and slip by ??

Don't think so. The clamp across the two halves and the nut holding down the clamp require that the stud be that high. I looked at it more yesterday...I'm stumped.

What about this? Should I double-nut the stud and remove it from the head? Is this something that is to be removed on a frequent and regular basis? On my twins, the stud is something this is quasi-permanent until someone uses too much torque and strips it out.

[schrader7032]

Here's a few pictures I took. The first one shows the exhaust cover off with the intake cover in place.



The next one shows the cover tilted towards the opposite side as far as it would go.



The last one is from a slightly different angle.

[c.d.iesel]

the later = "the stud is something this is quasi-permanent
until someone uses too much torque and strips it out."

I think your just not turning and rotating it
enough to reach the take off position - keep trying.

p.s. your spark plug is on the wrong side.

[schrader7032]

the later = "the stud is something this is quasi-permanent
until someone uses too much torque and strips it out."

I think your just not turning and rotating it
enough to reach the take off position - keep trying.

C.D. -

I haven't actually tried to remove the valve cover stud. I was just saying that on my twins, it is something I consider stays in place, generally not to be removed unless absolutely necessary. I feel that I should not have to remove this stud in my case.

Not sure who out there has an R25/2 or R25/3 (which should be the same), but I measured the distance between the top of the head to the underside of the frame backbone and I got 105mm. This is measured from the head itself, not the upraised land that the valve cover gasket sits on. It is measured exactly parallel to the valve cover stud. If someone has a bike with access to do the measuring, maybe they can measure it and let me know what their distance is.

p.s. your spark plug is on the wrong side.

Well, you would be correct if I had an R27!

[Bruce Frey]

I think I remember reading somewhere that the trick was to rotate the cover horizontally and then rotate downward as you withdraw it from the side so the rear (sloped) side of the cover is what fits between the valve gear and the frame as it is removed. It is also possible that I remember a different bike

Does the edge of the cover feel symmetrical? Could there be a flattened area that acts as a "gate"? Just a guess. I knew there was a reason I liked twins!

Bruce

[schrader7032]

Bruce -

I'll certainly try that. I'm usually pretty good with puzzles, but this one is baffling me. I'll feel like a dope if there's an easy way to do this.

Yeah, this wouldn't be a problem with either of my twins!

[schrader7032]

Someone else gave me a measurement of their R25/2 frame. From the lower engine mount bolt, measure the distance from the outboard middle of that bolt to the outboard edge of the tank mount bracket. I measured around 17.5 inches whereas someone else measured 18 inches. That difference of 0.5 inches makes a huge difference in my situation. I don't see anything on the frame that would indicate something has been bent. A few more measurements and I might have confirmed why I can't get the cover off.

Thanks...

[schrader7032]

I've heard from two difference sources for the measurement between the motor mount bolt and the edge of the rear tank support. The other two sources measure right at 18 inches whereas I'm measuring between 17.25 and 17.5 inches. So, I have a slight bend in the frame, likely the lower frame rail is bent slightly. I'll have to consider my options when I take it down for slinger cleaning.