If the flange is just flat I'd start tapping it with a rubber dead blow with all the bolts removed. You can also take a thin spatula and run it between the case and cover. You might want to bend spatula a bit to get in there. You have a picture of the primary cover removed to get an idea of the mounting surface. If you scratch or dent it, that becomes part of the history of the bike. Might want to get the bike hot before removal attempt.
In reply to Kenny_McCormic:
I don't actually run it dry, I just don't keep the primary full because it hemorrhages out of the primary case.
I lube the chain with an oiler through the inspection cover every time I take it out.
The primary isn't an oil bath, the oil level should be just below the bottom of the chain so it picks up a tiny bit to lube the chain but does not fling it all over.
If the clutch gets too much oil it will drag and make it very hard to shift.
Once upon a time you may have been able to make the primary oil tight but after this many years and having the covers on and off so many times, they get hard to seal.
I've even ordered the brand new, "improved" seal they make for my bike and it was no help.
I don't make any long hauls with it, it takes me to the coffee shop and back, a quick lube will be more than fine.
They're not industrial sprockets but they can be replaced if necessary.
Shawn
In reply to Trans_Maro:
Makes sense, it was the annual chain replacement bit that confused me. Are you doing that for fun or is it developing stretch beyond the service limit with the little use it sees?
I'm doing it because I'm sure my way will cause some increased wear.
After a ride, that primary chain is pretty hot. Even if there was oil in the case, I'm sure it will still get hot.
I have the cover off to adjust the clutch at the annual service so it doesn't really take anything to toss a new chain on there.
It's also some peace of mind. If that chain breaks, it will ball up a lot of parts that are worth a lot more and are harder to replace.
Shawn
What are the good sources for a new chain?
I'm trying to get the bike ready to hopefully ride the Moto Melee Classic this year. It's ~700ish miles in 3 days, with a support truck and a ton of old bikes, all pre 1970ish. I did the California Melee this year in the MGA and it was a ton of fun. A lot of the same guys do both events, definitly looking forwards to it.
If it's just standard industrial roller chain, you can have one made up nearly anywhere. Good hardware store, industrial power transmission shop, NAPA in a ag. heavy area, places like that.
This might a stupid idea and might not even fit, but can't you try with some fishing line? I have removed many parts and cut through nasty glue using that method.
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