Utility ATV repair and maintenance & Troubleshooting Place your Utility ATV Repair and Maintenance questions/thoughts here... *not performance*

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Old 02-19-2012, 06:04 PM   #1
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Trying to remove left side cover...

... on my 2004 400 Auto. Got the recoil starter assembly off as well as the 14 bolts holding the cover to the crank case. Smacked it a little in a few places and it's not budging... noticed this bolt (see attached) and it's not referenced or pictured in the service manual. Anyone know what this is and if it's holding the cover to the case? I would just go ahead and unbolt it but wanted to check first if anyone knows... would hate for this to release something inside and screw me.

Any other tips for removing the case (besides buying the $350 slide hammer)?

Thanks!
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Trying to remove left side cover...-catleftside1.jpg  
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Old 02-19-2012, 07:55 PM   #2
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Looks like bolt #19 on the parts fiche. If you are worried about internal issues I would loosen it off about 1/8" and tap the case inside to outside with a rubber mallet to see if it loosens up. If it does it has to come out. It's a long bolt (140 mm). Don't forget that you have some locating dowels in the cases which means the case has to come straight off. That's why you need to tap it out with a rubber hammer to get it moving.

Last edited by fossil; 02-19-2012 at 07:57 PM. Reason: spelling
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Old 02-20-2012, 10:55 AM   #3
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Thanks Fossil, I'll give it a shot this evening...
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Old 02-20-2012, 05:40 PM   #4
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Yep, that last bolt #19 was it, done deal.
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