In the process of adjusting my valves, I dropped an alignment dowel into my motor. I was unsuccessful when trying to retrieve it with a magnet, so I decided to remove the left-side engine cover. I removed the following: 13 bolts out of the side cover, 2 bolts out of the starter mounting bracket, the shift lever, and 3 bolts out of the water impeller cover (just to confirm there was no other hidden bolts). I have not removed the clutch arm nor the water impeller, I can't see how this would help. I've tapped on everything with a hammer and pried at the seam with screw drivers. No luck! What am I doing wrong?

Thanks for your help.

 

This is probably not it, but you have the cable removed from the clutch lever? If not do so and use it as a lever by turning it the wrong way, as well as some more love taps and it will eventually let go. I would refrain from sticking stuff between on the seam to pry.

 

The dowels in the case and cover may be sticking. They caused that issue on a re-assembly for my buddy and I. We ended up putting some assembly lube on them and the clutch cover went on much better.

I would agree, you should be able to use the shifter as a leaver to turn the clutch to push the clutch cover off.

Send me an e-mail if you need the parts manual (about 7+ megs so you will need a large e-mail account.)

 

you will also have to remove one of the bolts on the foot peg when you get the side cover to pop loose.