Removing gpz 500 rocker cover

[grem123]

Well my vernier arrived at last, so time to check the cam chain.

I am pretty clueless about this stuff, so is this the best way to remove the cover?

REMOVE THE PETROL TANK BY REMOVING THE SEAT AND UNDOING THE 12MM BOLT AT THE BACK OF THE TANK. LIFT THE TANK AND PULL OFF THE PETROL PIPES. DON’T LOOSE THE RUBBER BUNGS OFF THE FRONT. IF THEY KEEP FALLING OFF DAP SOME GREASE ON THE BACK OF THEM.

UNDO THE HOSE CLIP AT THE BOTTOM OF THE RADIATOR AND PULL OFF THE RUBBER HOSE. DRAIN THE COOLANT INTO A LARGE BOWL. DON’T LOOSE THE HOSE CLIP. ONCE THE COOLANT IS DRAINED REPLACE THE PIPE AND FASTEN THE CLIP BACK UP.

THERE ARE 2 COOLANT HOSES DISAPPEARING IN THE ROCKER COVER. UNDO THE CLAMPS AND PULL OFF THE HOSES. TUCK THE HOSES FORWARD OUT OF THE WAY SO THEY CAN’T DRIP ANY WATER INTO THE ENGINE. PULL OFF THE CARB COOLANT FEED PIPE OFF THE LH PIPE.

WITH THE IMPACT DRIVER UNDO THE 2 PHILIPS HEAD SCREWS THAT LOCATE THE COOLANT PIPES. USING THE NEEDLE NOSE PLIERS WAGGLES THE PIPES ABOUT AND REMOVE THEM BY PULLING UPWARDS. YOU MAY NEED PLENTY OF WD40. TRY ROTATING THEM UNTILL THERE FEEL LOOSE THEN PULL UPWARDS TILL THE PIPES COME FREE. BE PATIENT, TRY NOT TO DISTORT THE PIPES TO MUCH.

DISCONNECT THE PLUG LEADS FROM THE PLUGS. REMOVE THE LH COIL BUT DON’T DISCONNECT THE WIRE. LEAVE IT DANGLING OVER THE FRAME TUBE IN A MANNER LIKEY TO BREAK THE WIRES INSTEAD.

REMOVE THE SPARK PLUGS.

REMOVE THE 6 10MM BOLTS THAT LOCATE THE ROCKER COVER TO THE HEAD, AND REMOVE THE COVER. IT’S A TIGHT FIT IN THE FRAME TUBES BUT YOU SHOULD BE ABLE TO WORK IT OUT.


I have never worked on a bike, so to say i need step by step instructions is a understatement .

Why i am messing about in a clueless way, is it worth me removing my restricter too?(is in the carb).

Thanks for any input

[Kickstart]

Hi

I would also suggest you disconnect the throttle cables (they run fairly tightly over the rocker cover) and the coils (they get in the way of removing the rocker cover).

Removing the carbs to get at the restrictors is a pain, purely because of how limited the space is to move the airbox and carbs back, and also getting the tubes from the airbox to the carbs back on afterwards. Not technically difficult, just a long winded and fiddly pain.

All the best

Keith
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[grem123]

Thank you, off to make a mess i go