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  #1  
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94XLH 94XLH is offline
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Default Cam cover won't come off

I'm trying to take off my cam cover and it won't budge. I removed the rocker boxes to relieve any pressure, hit it with a rubber mallet to try and brake it free but no luck. I was able to pry it open about 1/8 of an inch with a screw driver but that's about as far as I can get it. I've pulled and pulled and pulled but it won't move. It's a 94 XLH 1200 so I'm guessing this is the first time it's been been removed. Any suggestions on how to get this off? PB Blaster?
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Take ignition out?
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Yep took it out.
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I would not bet there is 94 model out there has never had the cam cover off.
There are 2 dowel pins (1 behind the oil filter and one on lower left of cover).
Both pins are visible in the pic below.
These two areas are the best place to lightly tap (alternating back and forth).
I would not pry between the cover and case as that can destroy the sealing surface there.

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Thanks for the reply. I'm not sure I totally understand. Are you saying to tap in those places from the front or is there a way to get behind the cover and tap from the other side of the bike?
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You are going to have to tap the ends at an angle but in an outward fashion.
You most likely won't get a long stroke tap or hit.
But rather small bites. And really small bites is all you want anyway.

If you get one side to move out slightly, hold that side out with your hand and tap the other side.
Else you can tap the first side back in by tapping the other side.
This usually isn't such a big deal.

Those pins could be angled slightly if there is any warpage to the cover holding more pressure against the cover.
The only way I can figure the cams holding the cover on is if the bushings were heated up and warped.
Or an inner bushing seized to a cam shaft.
You do have all the bolts removed I assume.
All else equal, it's the pins holding the cover on.

You may try and bar on the left side just to keep outward pressure on the left while tapping the right side.
But be warned, you will be pulling against the aluminum case.
So just use light pressure outward while tapping the right side.
Prying between the cover and gearcase will result in oil leaks later.
Just baby it off.
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A tapered plastic pry/wedge tool is what I needed….tap tap tap as Hippy mentioned.


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I need a sanity check. I took out the ignition and the rotor cup. Is there anything else in here that needs to come out? It just seems like there is something still holding the cover on.

ing2.jpg
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Normally with both rocker boxes off, the only thing that could keep the cover from coming off is the pins.
Be careful when you do break it loose that the cams don't come fall out and hit something that will ruin them.
They will most likely want to come out still inside the cover.

Now if someone erroneously used silicone or some type sealer added to or in place of the cover gasket, that'd make it more difficult to come off.
But no, there shouldn't be anything else other than that.

Got a Slim Jim by chance?
If you've got an 1/8" space already, you may be able to slide it around inside the gap to check if sealer has a hold on the cover.
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Something like this (PLASTIC putty knife) might be helpful:



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