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I am doing a doohickey mod on my 2010 KLR and have hit a brick wall at getting my inner case off. I have successfully removed the flywheel and rotor. So to get the inner case cover off I have removed the 8 outer bolts and the one shorter inner bolt, as well as the doohickey. But I am having NO luck in getting the case to separate from where it attaches to the starter. I can pry the case away at the bottom end and get enough space to insert a screw driver blade, but I still can't get the top to pop off. In all the videos I have watched it looks like it shouldn't take much effort. I have tried prying the top off by inserting a screw drive between the case and the starter, but man it will not budge!! I have hammered away with my rubber mallet and reluctantly pried with a screw driver blade. I am worried that I am going to damage the case with my efforts (luckily I bought some new gaskets). It seems like I have missed a bolt or something. I count a total of 9 bolts, 8 outer bolts and the 1 smaller inner bolt. Am I overlooking something? I feel I am missing something obvious. Are my eyes bad??? :mad0235: Arg... thanx, Peter
 

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I did two of these and a third in participation but it was on Gen-I's and over 10 years ago. So, this is not info on a Gen-II.

8 + 1 for bolts sounds right.

Sticking around the starter sounds right. Sticking around the balancer eccentric shaft is also possible, but it sounds like you are past that.

My first thought would be a rubber mallet (as was yours). My second would be a dead-blow hammer with maybe a shop rag over the case. My third would be to drive a thin wedge (as in a wooden shim shingle) and taking it slowly. The wood will deform before the metal. ...but you would prefer that the case would come straight off.

Watch the idler shaft. You would prefer that it did not come out with the case.

I don't much remember having trouble getting the case off. I got the job done in about 4 hours I think.

Getting the swing-arm bolt loose on one of my KLR's took me 5 days and lots of PB Blaster.
 

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Sounds like the o-ring at the starter gear is giving you problems. Maybe liberally spray the area with WD-40 or the like.
 
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Sounds like the o-ring at the starter gear is giving you problems. Maybe liberally spray the area with WD-40 or the like.
And loosen the starter motor mounting bolts behind the exhaust pipe! Requires header pipe removal!
 
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