Transmission Cover Bolts Fiasco

[leonardhcross]

Hello all. I have read several posts regarding stubborn transmission cover bolts. Well, I wanted to add my story to the list. My bolts had been sprayed with PB Blaster since the day my project 76 GL1000 arrived here. I knew how difficult they can be. I am pretty sure that mine have never been loosened. Let me just say that I had all the right tools and tried all of the recommended techniques. In the end, after a four hour ordeal, my transmission cover came off. No bolts broken or heads stripped. The key for me was disassembling the whole front end. In order to strike the impact driver cleanly and with enough force, I needed swinging room. Even with the front wheel removed, my hammer glanced off the forks twice and hit my thumb. Ouch! Off came the forks. And....as soon as the forks came off, with all the weight gone from the front, the bike twisted and slid off the lift. I had tied the front end down and that really helped with a "controlled" slide rather than a crunch. So, for other week-end warriors like me......be prepared for a fight.

Bike After Tipping Over.jpeg

[dontwantapickle]

They can be a Real Pain to remove For Sure!
This is what I have been using for quite some time now. I haven't stripped out a screwhead since
using the impact with the right bit.

impact.jpg

[leonardhcross]

They can be a Real Pain to remove For Sure!
This is what I have been using for quite some time now. I haven't stripped out a screwhead since
using the impact with the right bit.
impact.jpg

Nice. Even with the crossmember in the way? Or, are you only doing this now with the engine out of the frame? Maybe also it would be helpful if you stated the JS designation for that tip.

[dontwantapickle]

The impact driver works even with the engine in the frame with a longer extension on a couple of the screws.
I'm not in the shop right now to check, but I'm pretty sure it's a P3 sized bit.

[low-side]

It's a tough job. When I did mine I didn't plan to reuse the screws, so my first step was to give each screw head about 5 heavy taps from the side with a drift and 2 lb hammer to break any corrosion between the screw head and the case and then soaked them in penetrating oil. Then, for each screw, I I tapped a P3 bit in and removed them with a 1/4" drive ratchet. I had a couple that took a couple tries, but they eventually came out without stripping. Took about an hour. I used Robin's stainless Allen screw kit for reassembly.

[pidjones]

I have yet to need replacement of the pump (luck of the draw). But, having pulled three engines so far, I believe that would be my route. May be a bit more involved, but you can take care of many other tasks while about it, and have full, unimpeded access to the transmission cover screws.

[5speed]

you could try this. It should clear the frame and gives you the ability to smack the screw straight on to free it up.

https://www.amazon.com/Handle-Screwdriv ... 116&sr=8-8

[Fred Camper]

The bingo method was the help I needed when I did mine. No broken screws.

[Sidecar Bob]

It is much easier on an 1100. If you can get them I would recommend replacing all of the JIS screws with the M6 with 8mm head screws as used on the 1100.

[Rat]

Robin sells a kit …

Gord

[Fred Camper]

Robin's kit worked well on BADDOG.