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Fxdrydr
Posted on Sunday, March 01, 2015 - 02:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Willing, but not the most competent or knowledgeable wrench.

Have a 2000 M2. I collected all the necessary parts and set about replacing the boxes.

Started with the rear and got all the bolts out of the cover - but the cover won't budge. Gave it a few raps with a wood block - still won't budge.

Thought about prying with a screwdriver but really want to avoid going ham-fisted right out of the chute.

Bike's sat for most of its life - only 2700 miles and bone-stock, which is why I'm thinking maybe the old gaskets are partially dissolved and sticking like glue.

Shop manual just says to unbolt and take the covers off... Pics and archives I've found here make no mention of these being difficult and I'm thinking they're just "stuck" on there.

Am I missing something? Is there a trick to getting these loose? Any suggestions?
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Oopezoo
Posted on Sunday, March 01, 2015 - 03:36 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Just popped mine off yesterday. I lined up a razor blade on the crease between the rocker cover and the spacer and gave it a little tap. I had to do it again between the spacer and the rocker boxes. Mine had the better rubber gaskets on them versus the original paper ones, but they were surprisingly VERY stuck in place. I didn't want to force anything either, but it certainly took more effort than I was expecting.
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Dannybuell
Posted on Sunday, March 01, 2015 - 03:43 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Get a dead blow hammer or a hammer and a piece of 2x4, give it a tap or two.
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Jolly
Posted on Sunday, March 01, 2015 - 03:55 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

^^^ yep, I had to use a 2x2 and a rubber mallet, "POPPED"...right off with a little encouragement, you don't need to litterly hammer it off, they can just settle in a bit if they have been bolted down too tightly and for too long with the old gaskets....

(Message edited by Jolly on March 01, 2015)
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Fxdrydr
Posted on Sunday, March 01, 2015 - 05:43 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks guys!
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Ft_bstrd
Posted on Sunday, March 01, 2015 - 06:32 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Just make sure you have all the bolts loose. Mine popped off without much effort.
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Harleyelf
Posted on Sunday, March 01, 2015 - 06:44 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

When you get around to the front, don't be afraid to clearance the new cover a bit to miss the frame. Stay out of the o-ring groove, metal needs to come off the top, not the side, of the part.

I reversed mine (front for rear swap) to miss the gas tank with the PCV valves; some guys have used two Blast covers.

What is sticking is most likely the rubber o-ring. I like the single-edge box cutter blade struck with a mallet idea best. Is your garage heated? If not, a hair dryer might soften the rubber gasket up a bit.
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Fxdrydr
Posted on Monday, March 02, 2015 - 10:37 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks Elf. I gave the rear a good whack with a rubber mallet and the top cover popped right off. Got my razor knife handy in case the middle sticks or I need it for the front.

I'll get to it a little more this evening.

It's in a heated space - heat is good!
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Harleyelf
Posted on Monday, March 02, 2015 - 01:35 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Glad to help. Remember that the middle section comes out and stays out. Hope your fuel tank clears the valves better than mine did.

My PCV valves were less than twenty bucks each at the dealer five years ago.

Wish I had a heated garage. Moved to Wisconsin from Florida in July and bought a house without heat in the garage just because it was cheap and had a big garage - rebuilt my VW motor in December with a space heater in my lap - can't even wash the bikes because the water freezes when it touches the metal.
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Airbozo
Posted on Monday, March 02, 2015 - 02:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I did the mod to my 2000 S3 and while it cleaned up the mess on the right side of the engine, I have oil coming out of the rear valve due to the tank sitting on it and/or hitting it during operation which causes it to move and allow oil to leak past it. I've tried elevating the tank as much as possible using rubber shims and such sticky backed rubber standoffs on the frame. Still looking for a better solution though.
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Harleyelf
Posted on Tuesday, March 03, 2015 - 03:17 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Try reversing the covers, that will give you a bit more clearance from the tank. You might have to replace the leaking PCV valve.

My '99 S3 wouldn't let the tank sit on its mounts until I swapped covers.
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Brother_in_buells
Posted on Tuesday, March 03, 2015 - 03:32 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Somebody on here mentioned to cut a piece of the rear breather and glue it back together.
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Fxdrydr
Posted on Tuesday, March 03, 2015 - 08:58 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well... I figured this upgrade is old news to folks here, but maybe still useful to some, so I'll post along as I do it and note any issues to overcome.

I'm going at this real slow - a little each day. Mainly because I have the bike in the storeroom area of my office at work and do a little before leaving - like therapy LOL!

The rubber oring/gaskets were stuck in the grooves and in some spots there is residue, so today I'll clean that out of there and get the grooves good and clean.

I've got the new covers all set and ready to install. Seems some run into the fitment issues you guys are talking about, and I found some threads where there were no issues and things went smoothly. I'll be finding out and making note. Bike's a 2000 M2.
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Oopezoo
Posted on Tuesday, March 03, 2015 - 09:16 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

good stuff. I'll be following along and hopefully doing the same conversion within the next week or so ('98 S1). I have it all torn apart right now to do the oil pump drive gear, crank seal, and grenade plate. The next XB rocker box covers will be installed when I put it back together.

My big debate is if I want to polish or paint them first
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Fxdrydr
Posted on Saturday, March 07, 2015 - 05:03 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I didn't get back to things until this afternoon and I finished it in a couple easy hours. The upshot is: it was extremely simple to do on my M2. No clearance issues with the tank or seat and the PCV valves. Minor clearance issue on the front cover, left front side as you're sitting on the bike.

After removing the old covers I thoroughly cleaned out the gasket channels of gasket residue from the old gaskets being dry and sticking. I just scraped it out with a small screw driver and carefully removed the debris so none could get into the engine and maybe clog an oil port. Used a rag and a little oil.

Then I laid the gaskets into position. The rear cover fit on easily. There was plenty of room to maneuver the cover into position and so holding it by the square hole in the center, I simply lowered it down without disturbing the gasket. Easy-peasy.

The front was tight. I already had the carb off but to make more room to work I also: cut the ties holding the wire harness so I could push it out of the way; unbolted the carb side of the top tie bar and swung it back out of the way; unbolted the horn - the bolt head was just catching the cover; and since the carb was off, I also swung the cables and idle adjustment cable out of the way.

I fit the cover onto the rocker box and could see exactly where it needed to be clearanced. I used a file, took my time and relieved just enough for it to fit correctly.

There's plenty of material and you really don't need to remove a lot. Just a little bit in the right area. I would file, then refit, see where it still touched (marked with a sharpee) and repeated until it fit.

I plumbed the hoses with a plastic Tee along the top left of the motor, down along the left side of the along the swingarm to just behind the axle where it's flush with the frame.

Still have other things to do and so haven't fired it up, but I'm pretty sure I got it right. Like I said, take your time, be careful with the gaskets and it's really simple.
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Buelldualsport
Posted on Friday, April 17, 2015 - 11:22 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Searched KV for part numbers for the conversion.

Any assistance will be appreciated
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Harleyelf
Posted on Friday, April 17, 2015 - 12:45 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Blast parts work, too.
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Buelldualsport
Posted on Friday, April 17, 2015 - 12:47 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Upper rocker covers

Gaskets

Grommet

Pcv valve
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S1owner
Posted on Friday, April 17, 2015 - 02:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Look at American Sport Bike they have a kit
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Buelldualsport
Posted on Friday, April 17, 2015 - 05:12 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

AL's kit has polished rocker boxes
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