Hey there, I just recently bought a 2009 Ninja 250r. I noticed when purchasing it that the previous owner had used some sort of "instant gasket" silicone like glue substance (idk what the correct term is) in replace of the gasket of the clutch cover. And as a result theres a small oil leak. I thought "easy fix, I'll just take it off, scrape away the sealant and install a new gasket." Oh how I was wrong!

After draining the oil completely (as much as I could.. there's still some that I can see in the oil sight that's reluctant to come out, even removed the oil filter to get any remaining oil out), I removed the bolts, clutch release shaft and oil refill cap. I then tried to pull the cover off as per usual. However it proved to be difficult, so I pulled harder... And harder.. and harder until I literally dragged the bike sideways along the ground.

So I got a flat head screwdriver and tried to get it between the seam and pry it open, that was unsuccessful.

I also tried getting a razor blade and tried to piece and break the seal, but all that did was scratch the cover a bit :/.

I then got a piece of wood and hammer and gave it a few good whacks all around the cover, and then several whacks against one of the pull tabs (there's two tabs, one at the top and one of the right for you to grab and pull the cover off, I placed the wood against the one on the right). I did this for at least half an hour, and got frustrated and gave a few really hard whacks... Nothing happened.

The only other thing I can think of is using heat to melt the sealant? But I'm worried it'll blister the paint. I also don't want to be too rough with it because the last thing I want is a cracked cover.

I also think that the cover was installed while the sealant was still wet, binding it to the case. I suspect this because when I removed the bolts, they had the sealant in their threads and a glob of it on the ends of them.

Any help would be IMMENSELY appreciated.



I've been trying to get this thing off for two days now 0-0
​​​​​​