Removing Outer Primary Cover

WEM

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I am having trouble removing the primary cover on my 1974 Roadster. It is possible that the outer primary cover has never been off the bike in 46 years. The three inspection port covers have been removed and I've tried using my fingers in the inspection ports to rock or break the outer cover free with no luck. I really don't want to put anything as a lever in the slot between the outer and inner primary covers. I'm considering a rubber mallet and/or heat but wondered if anybody has any other hints or methods they might have used to break the outer primary cover free before I go with heat and BFI (brute force and ignorance) methods. Thanks.
 

texasSlick

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A PO may have used some type of glue to seal the cover. Gentle heat with a rubber mallet should not cause any damage. That would be my first approach.

Good luck with it.

Slick
 
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Probably the rubber seal has degraded and bonded the case on. Rubber mallet or a block of softwood is probably your first weapon of choice but if that doesn't do I would resort to carefully try to get it with an appropriately sized screwdriver blade. Try tapping the wedge of the screwdriver into the joint rather than any levering action which may damage the aluminium.
 
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It's probably stuck on the dowels. Try the rubber mallet first it usually works.

Dave
 
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three inspection port covers have been removed
The cover is restrained by two hollow dowels
Two long pieces of wood used in the ports as levers to pull the cover off the dowels and break the bond? and shouldn't damage the port threads?
Rod got his off by igniting after filling with propane POP or was it bang?
not my first choice LOL
 
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Heat gun all around that very old seal edge. Rubber mallet taps all around after the heat soaks in. Don't scar the aluminum with screwdriver prisings. Soaking with nasty chemicals an option if this fails , then more heat and try again.
 

robs ss

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I am having trouble removing the primary cover on my 1974 Roadster. It is possible that the outer primary cover has never been off the bike in 46 years. The three inspection port covers have been removed and I've tried using my fingers in the inspection ports to rock or break the outer cover free with no luck. I really don't want to put anything as a lever in the slot between the outer and inner primary covers. I'm considering a rubber mallet and/or heat but wondered if anybody has any other hints or methods they might have used to break the outer primary cover free before I go with heat and BFI (brute force and ignorance) methods. Thanks.
If the above methods don't work (I would not condone either the propane or screwdriver (shudder) approaches) - a method that worked for me with a very tenacious cover is to make your own slide hammer. You will need:
  1. A length of threaded bar, say 12" (or very long bolt) about 3/8" or 10mm with nuts,
  2. A weight - anything of reasonable weight with a 10mm-ish hole in it,
  3. A large washer or piece of 3mm plate ground/filed to an oval shape such that when on the threaded rod, it can just be manoeuvred into one of the inspection ports.
Once assembled and inserted so that the washer/plate "hooks" onto the cover you can deliver controlled outward blows without damaging anything.
Works a treat!
Cheers
 

WEM

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Success! The primary cover is off. Thanks for the suggestions. A combination of patience, rubber mallet and heat did the trick. Next task is cleaning the 46 year old crud off the mating surfaces without damaging them. Anybody have any hints or tips they use for safely cleaning the mating surfaces? The 46 year old rubber gasket is pretty well petrified and will be replaced.
 
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Scrape the worst off with a plastic scraper and then rub the
rest off with methylated spirits using a strong cloth.
There are bound to be better stronger chemicals, but Meths worked for me and is cheap and easy to get.
 
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Scrape the worst off with a plastic scraper and then rub the
rest off with methylated spirits using a strong cloth.
There are bound to be better stronger chemicals, but Meths worked for me and is cheap and easy to get.
Outdoors only or with the garage door open. Use plastic gloves resistant to chemicals.
 
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46 years of not being inside the primary ??? What was the inside of the cases look like, chain, clutch, alt and rota, condition of oil if any still in there etc, if the bike was maintained in all those years when on the road I am sure it has been opened, or has it been sitting in storage for a long time, do you know the history of your Norton, mileage etc, servicing the primary is the same as doing oil changes on your motor and part of general maintenance.
I am lucky with my Norton as I know its full history as I have owned it since new and all the changes I have done to it, every thing done by my own hands, but not everyone is lucky like me, regular maintenance or yearly maintenance depend on how many miles you clock up each year, but if its been in storage then very important to go through every thing, not just the primary.
Good time to pull the clutch apart and give everything a good clean and inspection of everything inside the primary, its not a hard job, a clutch compressor tool is easy to make to release the clutch plates, a workshop manual is your best friend.
Good luck with it and if you get stuck you know where to come for help here.

Ashley
 

Time Warp

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If you have to bash something between the inner and outer covers at least consider a fox wedge, the flattest angle one and to a knife edge, they even come in plastic and stainless steel which can be further enhanced by polishing.
 

jaydee75

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Glad you got it, but I have used razor blades as a slim wedge to pry cases apart. Done carefully, it won't leave a mark.
Jaydee
 
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46 years of not being inside the primary ??? What was the inside of the cases look like, chain, clutch, alt and rota, condition of oil if any still in there etc, if the bike was maintained in all those years when on the road I am sure it has been opened, or has it been sitting in storage for a long time, do you know the history of your Norton, mileage etc, servicing the primary is the same as doing oil changes on your motor and part of general maintenance.
I am lucky with my Norton as I know its full history as I have owned it since new and all the changes I have done to it, every thing done by my own hands, but not everyone is lucky like me, regular maintenance or yearly maintenance depend on how many miles you clock up each year, but if its been in storage then very important to go through every thing, not just the primary.
Good time to pull the clutch apart and give everything a good clean and inspection of everything inside the primary, its not a hard job, a clutch compressor tool is easy to make to release the clutch plates, a workshop manual is your best friend.
Good luck with it and if you get stuck you know where to come for help here.

Ashley
46 years is like forever to not get in there for sure.
The possibilities for upgrades and maintenance are enormous.
Good luck.
 

cliffa

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I know it's already off, but why not just (carefully) run a breakoff blade knife around the whole case to cut the seal in two, as it's going to get replaced anyway?
 
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