Bad fit!

[HrdnSwede]

Hi there XS peeps!
Got myself a project bike awhile back and am working on getting it out this summer. Mostly taken apart so it's like a LEGO for sure! Noticed after glas bead blasting the generator cover that it doesn't line up at all over the drive sprocket... (The engine is a 1980/81 TCI) Are the cover different for a 'points' engine since they don't have the pickup in there? Or is this 'normal'? (Seams unlikely to me since Yamaha usually makes high quality stuff...)
Another thing in the same area is that I got a new, one peice, clutch rod and hence needs to get the old one out. Is there a way to get that done without yanking the seal? It's new, previous owner changed it.
(Yes I know there is a cracked in the case, gonna weld it. And I did cut off the giant 'wing' over the chain if that helps with explaining where you are looking.)

Thanks!

 

[TwoManyXS1Bs]

First time I've seen a cover warped upwards like that. Look like the tail extension (mates with chainguard) was sawed off, which would allow that overhang to freely dangle, and possibly bend, maybe from released casting stress. Could check for marks from a thrown chain.

http://www.xs650.com/threads/warped-side-cover.37538/

http://www.xs650.com/threads/left-hand-engine-covers.32250/

Member dps650rider used superglue to extract his 2-piece pushrod.

http://www.xs650.com/threads/xs650-clutch-pushrod-experiment-tidbits.32267/page-5#post-347148

 

[HrdnSwede]

I cut the guard off and it looked normal and undamaged before the cut. I'm thinking a chain broke at some point too with the case. No biggie, I'll just weld that up when I got the engine out.
The super glue makes total sense! Thanks for that one!

 

[TwoManyXS1Bs]

Maybe the casting just sprung.

Didjaever cut a ring from a pipe, then slice the ring open?
*sproing*, and the ring opens a bit....

 

[gggGary]

With that cracked case I'm betting on chain violence.. Chain skipping over the sprocket drives that tang up. Maybe pushing the back of the cover up with it.

 

[HrdnSwede]

That's likely too gggGary. I just thought it might been the wrong year, but seams like the only difference on these is a square corner on early model years.
I'll see if I can bend it back down. Actually though of cutting it even more for a different look than most but think it will be weird since I have to keep the clutch cable hole and it might not be strong enough for that. A spungy clutch lever ain't cool.