1982 GS750T - fitting tachometer drive gear... Did I screw up?

[SamLack99]

Whilst waiting for bits from CMSNL to arrive, I thought I'd install the tachometer drive gear back into the cam cover.

Reviewing my Clymer Suzuki GS750 Fours 1977-1982 manual, this snippet on page 105 sent a shiver down my spine:

[QUOTE]CAUTION: The Tachometer drive gear must engage the camshaft as the cam cover is installed or the gear will be damaged when the cover bolts are tightened.[/QUOTE]

I'm concerned because I have already fitted the cam cover, and sealed it with Permatex Ultra Black gasket maker.

And I can't get the tachometer drive gear in.

I removed the ignition cover and used a 19mm wrench to rotate the crankshaft whilst trying to get the tachometer drive gear into the cam cover.

But it simply won't go all the way in.

05-suzy-valves.jpg

But when I re-read page 9 of Valve Adjustment for 16 Valve Motors I found this snippet:

Also reinstall the tachometer drive gear and cable. If needed, replace the O-ring. If not, just slide it back in. I put a little bit of PB oil on it to help it slide back in. It may take a bit of twisting of the housing to get everything lined up properly and the housing to slide all the way in. Reinstall the locking plate and bolt and tighten.

This paragraph comes after torquing the bolts of the cam cover.

So finally my question...

Am I going to have to remove the cam cover to fit the tachometer drive gear or do I just need to persevere with wiggling it in?

Thank you =)

[SamLack99]

Another picture:

04-suzy-valves.jpg

[Rich82GS750TZ]

I've reinstalled the valve cover numerous times and pretty sure I've done it both ways. It's definitely easier if the tach drive gear in installed in the cover before you drop the cover onto the head. I'd try to keep wiggling it while also turning the crank shaft (clockwise looking at the ignition side). It should go in, but I believe I may not have had everything snugged down when doing it this way.

I'm more concerned about the use of the permatex either alone or in conjunction with a proper gasket to seal the valve cover to the head.

[SamLack99]

Thanks Rich,

I'll see if I can wiggle it in.

If not, I guess I'll take a deep breath and remove the head.

And then take it as a sign that Permatex wasn't a good idea.

I'll keep you posted =)

[Rijko]

i had the same issue on a GS1000, new imitation tacho unit.

Tried to stick the whole unit in and failed just where yours is at.
Made me wonder just where the issue was.

So first i took out the worm wheel and could wiggle that in.
Next i took off the o-ring and could slide the housing in easy.
Next test - housing without wormwheel but with the (oiled) o-ring on ... would not go in.
O-ring was way too fat, a thinner one and all was well.