Suzuki 2 Strokes

Sealant + gasket was used. 100% sure all the screws are out. Pounding with a rubber mallet has not freed the cover.

Question: is there a slide hammer tool for blind holes that would work on the M6 cover screw holes?

Any other tips?

Do a 200% check thar all screws are out.

Already 300% checked. Removed all the screws. Using a mirror, checked entire parameter for only holes without screws. Counted the number of removed screws.

Silly question perhaps but did you remove the clutch actuating rod adjusting nut and lock nut?

If so there are two dowel pins that locate the cover and may be tight.
If all else fails use a small flat plate with three 5mm holes to hold onto the cover and one large threaded hole for a bolt to push the cover off but it should come off with very light hand pressure on the wrench on that center bolt which will press against the clutch actuating rod.

I find one of the most useful tools in my arsenal is a heat gun.
Perhaps a bit of warming would help the sealant relax its grip.

Mitch

Problem solved.

The cover & crankcase match nicely on the top, as one would expect. But on the bottom where nobody looks, there is a bit of a lip. A modest lateral tap with a rubber mallet & junk screwdriver freed the cover.

I had tried heat after reading FullMoon's post but it still didn't budge. Was moving the motor some hours later & noticed the lip on the underside.
So perhaps it was the combo of heat & modest lateral tap.

Thanks, for the tips.