Topic: This Can't Be Good

[Gordo]

While starting up the bike today (k6 750) I noticed a spark appearing intermittently right here between the case and the cover


complete with little puffs of smoke. The heads of the cover screws are, of course, completely stripped so I will have to remove them with an extractor or drill the heads off. Fortunately I have a set of stainless hextop bolts waiting to go in.

1.) Does anyone have any idea what I might be in for with the mystery spark?
2.) What is your preferred way to get stripped screws out?  Drill or by hand?

All thoughts appreciated.

[mkramer1121]

Your neutral switch, starter wire and all the wires that go to your stator run under there.  Probably have one that the insulation as apart on.

[Jonesy]

I'd focus on the alternator wires (3 yellow, one white and one green). The oil pressure and neutral switches are on the ground side of the system, so if either one was shorting out the indicator lights would come on/flicker. The heavy cable for the starter only has current going through it when the solenoid is closed. If the sparking only happens when using the electric starter, it could be in the starter motor cable.

It won't hurt to look them all over, but the alternator wires have current in them as long as the key switch is on, so I'd start there. Sometimes the wires can get pinched in there.

Try an impact driver or screw extractor on the sprocket cover screws first. The cover has to slide towards the back of the bike a bit before it can be removed, so drilling the heads off won't really allow for removal. You could also try Dremeling a slot in the screw heads and getting them out that way...

[TEET76]

ditto that last comment, probably a wire grounding. I just removed all my stripped phillips screws by using a drill, drilling slightly larger than the diameter of the threaded area of the screw. When the bit starts penetrating past the head the head was weak enough to come off without any damage to the cover. So when I was done it looked like a bunch of studs sticking out, but you can unscrew them with your fingers most likely like I did. I got a few off with my impact driver, but the rest had nothing left to bite on to.....SO...after removing the  Sprocket cover first.......the shift linkage cover can be manipulated off, I tried using a dremel to slot the heads, but the recesses in the cover left the possibilty for damage...

[Gordo]

all becomes clear - I just replaced the battery, now I know why the old one was draining out...

thanks guys.

[Jonesy]

SO...after removing the  Sprocket cover first.......the shift linkage cover can be manipulated off, I tried using a dremel to slot the heads, but the recesses in the cover left the possibilty for damage...

I hadn't thought of the shifter cover, but that also covers the wires. As a last resort, if you have to drill the heads off the screws, the shifter cover could be removed first and then the sprocket cover can then be pulled straight forward and off the engine. (Good point, TEET76!)

[TEET76]

Thanks for the comment jonesy! I just removed all my covers yesterday to replace the gaskets, and install some new stainless cap screws, and almost every friggin screw was stripped bad....I guess whoever was tyring to get in there previously, decided not to after mangling half the screws.....I was very nervous drilling them, but it was a last resort, and thankfully it worked for me

[754]

I cut part of my sprocket covers off at the back.. easier to re and re..

[Gordo]

Got all the screws out with ye olde screw extractor. Whew.

All of the wires were filthy - and just to confuse me they weren't sparking when I turned the bike on with the cover off.
So... I'll clean them in the morning and see if I can tell which one was sparking then (though it is easier to see the spark in the evening). None of them were obviously stripped.

So now for some more NEWB questions:
1. Is it normal for about 3/4 cup of oil to come out when you take that cover off? or does that mean $$$?
2. I have a gasket for it, do you recommend gasket sealer when I re-assemble?

[Patrick]

It is normal for oil to come out when you remove the shifter cover. I, personally, don't use gasket sealer on side cover gaskets. Almost any gasket, for that matter. They seal just fine with a light coating of grease on the gasket and it makes it easier to remove the cover again without ruining the gasket, if you need to.