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Removal of the front engine cover isn't difficult, though there are a few steps to it. Things you won't have to remove:
Things you will have to do:
It is possible to remove the cover with the engine still in the bike.
As part of the triple bypass procedure, though, your motor is likely to be out on the bench like so:
To remove it from this point all you need is an 8mm socket:
There are thirteen bolts holding the front cover in, all of which are identical 6x28mm flange bolts. There are three part numbers associated with them - 96001-0602800 (eBay), 90006-413-000 (eBay) and 96000-0602800 (eBay)... though that last one doesn't seem to have any results. Bolt locations:
Clean the heads before you try to undo the bolts as they're pretty small and extra dirt and grit which prevents you from getting a good purchase might mean a rounded bolt instead of a removed one. We like to break them all free in a criss-cross pattern and then remove them in a second criss-cross go-round. Count the bolts, check and double check that you got them all.
There is a single gasket between the front cover and the block - part number 11391-449-306 (eBay) - which can provide a fairly firm grip on the front cover, particularly if it's been there for a long time. There are also dowels on the front cover which prevent you from rotating it free. One way of getting the motor to do the work for you is to put a wrench (adjustable or whatever you have that fits) on the clutch actuating arm - where the cable attaches - and pull it as though you were pulling in the clutch cable. The front cover should push itself away and break the seal at that point. You could leave the clutch cable attached and use the clutch lever for this, and disconnect it after the cover is removed.
Once the front cover is removed there is a chance that a handful of things fall out; firstly, the clutch lifter rod (22847-415-000, eBay) may fall out of the recess in the center of the clutch cover - make sure you don't lose it:
Next, there is a small oil orifice - or there should be - just to the outside of the gearbox/clutch, on the left as you face the front of the motor. For the CX500 and GL500 it's part number 11132-415-000 (eBay), and for the CX650 and GL650 it's part number 11132-MC7-000 (eBay):
Note: The above photo shows it having been inserted by the previous person in the wrong orientation! For the correct orientation, see here. There is also an O-ring which should be sitting around it, which sometimes falls off:
The 8x1.7mm O-ring is the same part number for both capacity engines, 91303-001-000 (eBay) or 91306-HB3-003 (eBay).
There are several other dowels and O-rings which may fall off or out when you remove the front cover - to see them covered in more detail check out this page. We like to take out anything that's likely to fall out and stick them in a marked ziplock bag.
Once the front cover is off you should be able to see the clutch assembly and the oil pump clearly:
If you have to leave the engine for any length of time it's not a bad idea to put the cover back in place loosely to prevent foreign objects from finding their way in there.
If you are doing this as part of a triple or quadruple bypass, click here to go back to the bypass page.
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