Removing right side crankcase cover?

[sprint_9]

Any recommendations on an easy way to get that damn thing pryed loose, mine is welded on there.  The stupid gasket leaks but sure holds itself on there well.

[Rashad]

Try a screwdriver (GENTLY!) in each corner until its slightly looser, than keep working it. You will have to scrape that edge to get the gasket off anyway.

[sprint_9]

Yea I tried the gentle apporoach at first then I got the hammer out to assist my prying methods and its still on there.  Your suggestion did spur on an idea that I think I will try though, the main problem is you cant get anything in there to pry on it because its so confined around where you need to work.

[se7enty7]

Yea I tried the gentle apporoach at first then I got the hammer out to assist my prying methods and its still on there.  Your suggestion did spur on an idea that I think I will try though, the main problem is you cant get anything in there to pry on it because its so confined around where you need to work.

there are a couple of 'tabs' (or dog ears?) on the front and rear... I lightly pried it off using a large screwdriver and pushing against those tabs

[raindrift]

Did you get the two bolts under the timing cover?

[Rashad]

Ok..make sure you got those bolts as mentioned...

THEN... take a rubber mallet and wack every part of the seam...repeatedly...then repeat.

[sprint_9]

Did you get the two bolts under the timing cover?

That could be one problem. I knew I should have looked in my Clymer.  Stupid, stupid, stupid (hits self) :mrgreen:

[Blueknyt]

Be super careful, those threads are weak, the bolts are odd length, ive stripped out those threads ended up taping out to larger diameter, Epoxying the bolt in place, cutting the bolt flush then redrilling and taping to stock size, its not fun, fact its nerve racking as hell as those bolts hold pressure for the oil galley for Counterbalance shaft bearings. Yet another reason to have the crank rebalanced and get rid of that parasitic chunk of steel.

[sprint_9]

Yea that looks like quite the system Suzuki designed, talk about a stupid design.  The cover did come off alot easier once I got all the bolts out, I usually learn things the hard way, learned this time to use my manual first.  Thanks for your help.

[Iautorico]

Hey what bolts are under the timing cover??? I had three small exterior bolts for the outside... pulled the rotor bolt. Is there something behind that ignition plate?

[ben2go]

Yep they are under there.