I've removed all the bolts and got the sprocket cover off, but the cover (part #14 in the Diagram (http://www.bikebandit.com/PartsBandit/Assets/schematics/Suzuki/SU0083_006.gif")) still willl not move. I dont know how much effort is supposed to take, so I'm just trying not to break anything.
Is this part even supposed to come off? And is there oil behind there?
Also, once it's removed, do I have to replace the seal, or can it be reused?
Thanks.
(http://img130.imageshack.us/img130/41/leftsidecover0mh.th.jpg) (http://img130.imageshack.us/my.php?image=leftsidecover0mh.jpg)
clicky no worky!
Yep, there's oil in there. And far as I know there are no concealed bolts on this cover, so try tapping it loose with a rubber mallet.
Yes, drain the engine first before removing the generator cover.
The gasket you asked about does exist and is what is causing you to have such a hard time removing the cover. Unless it's brand new, it's cooked onto the engine and the cover forming a great seal for the case but making your life difficult.
once all the bolts are removed (they'll all be visible looking straight at the cover) there are two things holding the cover on still. The main one is the aligning pins. These are hard to put into words but they make sense when you see them. They're just cylinders that go around two of the bold holes to make sure the cover stays aligned. Check them out as number 16 on your diagram. The other thing sticking is the gasket.
So, there should be a tab that sticks out from the cover and that helps in prying the cover off. A rubber mallet works for loosening the gaskets hold but it'll be near impossible to swing a hammer in such a way as to move the cover off the engine. Once the cover comes loose in one spot you will be able to work your way around its edge and loosen it. Work the edge with something that wont scratch the mating surface! I think I just put duct tape over the end of a flat head. As you start to get more and more separation between the cover and the crank case, you can get more and more in there to pry with. Make sure to work your way around evenly, again being careful not to scratch.
The last thing you'll notice before you think your stuck again is a loud "clink" and your cover moving over. That's just the magnets of the generator coil grabbing onto the flywheel. Don't worry, just keep sliding it off.
I guess the one tricky part there is that your generator coil is bolted to the inside of this cover you're removing, so it's got wires that don't want to go with it. You'll figure that out.
Your gasket is going to break. Especially if this hasn't been done in a while. Don't try and save it, just get a new one (I already made this mistake and it's not worth your time). The hardest part is removing the left over gasket material from the cover and from the crank case. it's important to have this surface clean. In fact, unless the gasket is only 50 miles old, this will be the longest part of the whole ordeal. Just get your favorite wood chisel (sharp) or some such tool, maybe soak the gasket part of the engine cover in soapy water for a few hours and go to town. remember, be careful not to scratch too deep or else the new gasket wont seem anything in.
Thanks for the detailed post, Shady.
On aluminum I use a plastic drywall scraper that I sharpen with a file so I don't gouge the aluminum. But then I'm kind of anal about things like that
SHADYRAY great write up :thumb:
one thing to add. there is a lip at the bottom right hand corner of this cover. it is possible to use a claw hammer and pry the case off at this point.
be careful, though. also the magnets are strong and will require a bit of force to pull the cover off. at first I thought I had forgotten something. Good luck :cheers: