Rear gear cover removal

[bmccaffry]

Hi guys. I have a 1994 honda elite sr. I have some taller gears coming in tomorrow and I am taking apart today. I have the clutch out and everything but I can not get the gear cover off!! Is there any tricks to this? I know its aluminum so I dont know how hard to pry or if I should pry at all?? Please help!!

[Wheelman-111]

Greetings:

Gasket turned to Epoxy? It can happen in 16 years.

I suggest you remove the rear wheel to gain access to the gearcase from behind. You will see a couple of places where you can apply a drift, punch, oe big screwdriver.

Tap-tap rather than Whack. There are a couple of locating dowels so it helps if you keep the cover aligned with its plane of installation.
Work one side, then the other. The clutch shaft provides a handle that you can wiggle up and down as you go.
The steel dowels corrode Galvanically in their Aluminum holes, so consider replacing them once the cover pops off. Threr will be more oil than you might expect when the seal breaks, so avoid working on your
Priceless Persian rug.

A liberal slathering of all surfaces with bearing grease will facilitate the next disassembly.
Good luck!

[bmccaffry]

Thanks wheelman...I got the rear wheel off and just dont see any good place to tap? Im sure Im over looking somewhere !! Ill keep trying!

[bmccaffry]

Hey wheelman.Thank-you for your advice! Got it off. Nasty oil. Gray color. But I can fix that now. Will these same washers work? I also destroyed the gasket. High temp silicone work ok? Thx!

[Wheelman-111]

Greetings:

The gasket serves as a spacer as well as a sealant so negative on silicone goo.
Without a gasket, you run the risk that the ends of the shafts will be pinched. Get one for $6 at Honda. The '94-early'98 are different from late '98-2001.
Make sure they order the right one.

[Palero2003]

ill post here also dry not trying to * but do you know what part number gasket is?

[Wheelman-111]

Greetings:

Every big Honda-san-Approved dealer has an online Parts Fiche that lets you look up anything from almost any year. That's Deepinnaharta Honda's version. The dealer PartsDude loves it when you call and just read him the part number. Sometimes I get a discount because I save him the work.

Be aware the '94-early '98 transmissions use an entirely different cover and bearing setup as well as a different-diameter rear axle from the late '98-2001 SA50s. The gasket part numbers are different, and when you hold one up against the other, you see that the cutout channels are different too. Make sure you match the gasket to the correct model year if you can, although Some believe it doesn't matter. I trust Honda-san's engineers over Some.