80 gs1000GL, can't get valve cover off

[Guest]

Decided to adjust valves on my 80 GS1000GL after doing my 78 GS1000C. The valve cover came off pretty easy on the 78, but the 80 GL cover gets stuck in the front where the hump is for the exhaust cam gear. I have removed the breather cover, that is not the problem. I have tried wiggling, starting in front first, back first whatever, it is not coming off. Anyone have a clue or am I going to have to loosen the engine?

 

[Steve]

Loosening the engine won't help. You can tap it lightly sideways with a hammer to see if that will break the bond, or start at one of the corners to pry it up gently.

When you get ready to put it back together, be aware that six of the 16 bolts are longer than the other ten, they need to go in the proper places. Hopefully it's not too late, but the best way to keep track is to draw the shape of the cover on a piece of cardboard, punch 16 holes in the appropriate places, then put the bolts in the cardboard where they came out of the engine.

.

 

[Guest]

I have broken the bond, it is the lack of clearance between the frame and the protruding end of the cam cover that physically won't let me remove the cover. Is that any clearer?

 

[Steve]

Clearer, but still puzzling. :-k

I have seen them with tight clearances, but always room to remove the cover.

.

 

[Grimly]

On mine, the harness and other gubbins sag and prevent a clean removal. You might look at it and swear there's enough room, but there isn't quite.

 

[eil]

Dealt with this a little bit yesterday on the 850GL. It feels like I have to re-learn how to get this dang thing off every single time. Like Grimly says, the spark plug wires and electrical connectors make for a very tight fit to get the valve cover off. You might need to wiggle them around and push them up and out of the way as much as possible. If all else fails, you can try removing the ignition coils just to get the spark plug wires out of the way.