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Trouble Removing Generator Cover (CG125 2005)

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Falco
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Joined: 26 Nov 2015
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PostPosted: 13:12 - 06 Mar 2016    Post subject: Trouble Removing Generator Cover (CG125 2005) Reply with quote
After managing a sort-of functional repair on the generator cover, I thought I would pull it off today and give everything a clean (and see how it all fits together) prior to the new cover arriving on Wed/Thurs.

Unfortunately I have already hit a problem....it won't come off. I have removed all the bolts I can see:
https://i65.tinypic.com/313ps2r.jpg

but it still won't budge Confused How much force is needed (I suspect it has never been off), I don't want to start yanking it or thumping it if there is still a retaining bolt or something holding it in. I feel like I am missing something but what?

P.S. I've removed the started motor since that picture but still no luck.
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Rob Fzs
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Joined: 07 Oct 2015
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PostPosted: 13:16 - 06 Mar 2016    Post subject: Reply with quote
Put a block of wood on it and tap it with a hammer, should release
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Falco
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PostPosted: 14:03 - 06 Mar 2016    Post subject: Reply with quote
Rob Fzs wrote:
Put a block of wood on it and tap it with a hammer, should release


Thanks. I gave that a shot but it didn't budge an inch. Should I be trying to hammer it in a particular direction? I tried mostly from the right hand side (i.e. through the frame of the bike) and from above but its not for moving.
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Vincent This post is not being displayed because the poster is banned. Unhide this post / all posts.

Falco
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PostPosted: 19:45 - 06 Mar 2016    Post subject: Reply with quote
Vincent wrote:
Stick your finger in the hole and pull outwards while tapping around the edge with a wooden mallet, (actually, as it's scrap you can use whatever you like, just don't hit the crankcase). There'll probably be a dowel that's keeping it in place, once that loosens off, it should come free.


Tried it with the mallet but still no luck. Decided to pry the cover off the...little bulbous thing? on the top of the cover and what did I find? Another bolt! Glad I didn't hit it too hard now.

https://i67.tinypic.com/25iol88.jpg


So I took that out and the cover came off no problem (in part because there is no gasket left at all...just a green coloured smudge Razz).

Sadly another issue has emerged. There is a wire running into a rubber thing (sort of like a tiny rubber bung with a hole in it) in the side, just below the bulbous thing. It looks like it slides out (though it is a bit stuck) but before I start yanking at it I was wondering what it attaches to? Does whatever it is linked to need to come out as well or should I just detach the wire and take it out later?

Sorry I can't give a picture but the angle is just so damn awkward as the cover won't come all the way off before the wire goes taut. I'll try and get a picture in daylight tomorrow.
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mudcow007
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Joined: 01 Feb 2012
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PostPosted: 20:08 - 06 Mar 2016    Post subject: Reply with quote
neutral switch/ wire?
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Falco
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PostPosted: 23:50 - 06 Mar 2016    Post subject: Reply with quote
mudcow007 wrote:
neutral switch/ wire?



Ohhhhh, very possibly. Looking at the Haynes manual it looks like it might in fact be the alternator wiring as the picture shows it going into a similar rubber bung at the right area. Will take the sprocket cover off and have a look anyway. Cheers for pointing me in the right direction!
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Old Thread Alert!

The last post was made 9 years, 352 days ago. Instead of replying here, would creating a new thread be more useful?
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