Removing LHS engine cover on ETZ 250

[JawasandMZs]

Hi, I'm trying to get the aforesaid off to renew the kick-start return spring. Having removed the 5 screws and removed the (defunct) oilpump and undone the rev counter drive cap the engine cover will only come away about 3mm away from the gasket surface. I don't want to prise it too hard and break something, but something is def stopping the side cover from coming away. It's driving me mad.
I can get the LHS engine cover 3mm away from the gasket surface at the back of the engine at 2mm at the front. There def a gap all the way round.
Help!

[Kruh]

On which side does it seem to be stuck? Around the kickstarter or clutch.

Likely the bearing is a stuck on the crankshaft. For that you can make a puller from a flat piece of metal - drill holes where the clutch cover holes are and one in the middle for a screw which will pry against the crankshaft.

[JawasandMZs]

Hi kruh,
Thanks for your help. That sounds like likeliest reason. What about a heating up around the shaft?

[Blurredman]

Make sure all the bolts are off (5 that attach the clutch cover to the crankcase), plus additionally the tacho drive nut- some people forget this. Normally I have the clutch cable entrance tube attached an with left hand on that, and right hand on the kickstarter, I pull it off thus. It can be a pain sometimes as it is a close fit (ie crank end and gear shifter shaft) not giving much movement. Don't forget the shift lever!

[JawasandMZs]

Thanks Matthew. Does that mean I lock the crank using your rope down the hole trick then remove the nut from the crankshaft? That sounds pretty easy. Thanks!

BTW I need to change the swing arm bush next.

[JawasandMZs]

Result!!!!!

Job done in ten seconds!
Thanks again.
Naughty Haynes manual never mentioned that nut.

[dave47]

Naughty Haynes manual never mentioned that nut.

Yes it does!
Haynes manual for ETZ250 is quite good, unlike the TS manual.

[Puffs]

Yes I find the Haynes manual pretty good too; chapter 1, sec.8.2 (P41).
The original factory manual is equally clear in '3.2.2. Abbau des Kupplungsdeckels'.

But it can stick & Kruh's trick is slick.

[Blurredman]

Presumably you are only doing this because the spring has broken?

They don't often break- I haven't had them break on me, though my brother's ETZ250 it did break once.

[JawasandMZs]

Hi Matthew Yes. The kick-start spring had broken off at the point where it goes into a hole in the side of the engine case. I remember reading somewhere like Used Bike Guide that whenever you rebuild an engine it's a good idea to routinely renew any internal springs as they DO occasionally break and it just saves hassle in the long term .

Oh and btw I noticed recently how noisy the rev counter drive off the crank is so removed it and blanked off the orifice. Def quieter now.

Thanks again.