Hey there gstwiners

Once again this isn't about my gs although i am thinking of keeping the busted up gs as a project bike/track bike for a bit of fun. Finally got my insurance settlement for the crash, 4200$AU which is pretty fair.

The problem ive got at the moment is fixing up my Suzuki across. Ive taken a few photos and hopefully someone on here can give me some advice.

First off when the bike low slided it ground a hole in what i think is the rotor cover? or clutchside engine cover?



So what i did was drain the rest of the oil out as most of it had already leaked through that small hole. Then i took off the 8 bolts that hold the cover in place. I was planning on cleaning it thoroguhly with break cleaner and then taking it somewhere to be repaired, or perhaps use something like QuickMetal, stil not sure.

Anyway when i tried to take it off i was unable because of a yellow wire going to the stator motor



Any ideas how thats supposed to be removed without cutting those wires??

Couple of other things too:



Should i just try and scrape that rust coloured stuff off with brake cleaner? It looks like a liquid but its very solid


IS this the airbox cover that i am missing? Could this be a possible reason as to why the bike was running rich prior to the accident?


Also prior to the accident the left side indicators wouldnt blink. Now both sides dont blink so i removed the flasher relay


Any idea where i can get a replacement one of these? tried all the usual car and electrical stores and none of them seem to supply them.


I'd Appreciate any help
Roshan

Woah there. Get a service manual! You can even find one online for free without trying too hard. Don't just go taking stuff you can't even name apart. Are you really running without an air filter in your airbox? Really? I sure hope you didn't lean your bike out if i was running with no filter because it was already running crazy lean. Have you ever looked at your spark plugs? I'd bet they're super white. You need to slow down and read some before you go any further. A service manual will give you step by step instructions and pictures of everything. It is a wonder your bike is still running and hasn't run out of oil or overheated and seized.

Nothing i took apart cant be easily put back together. needed to take pictures so someone with more knowledge than me could give some advice thanks. the service manual i found online has really poor quality photos and cant really discern much from it. Had a look at the 4 plugs and they seemed to be in good condition.

If I was you I would join the Across owners forum and start asking questions in there.

http://au.geocities.com/ozcross250/maintenance.html

The "rust colored stuff" is electrical insulation and should not be removed. As for the yellow wires, trace them through to the main wiring loom, they should go to a plug connector near the battery, and unclip them there, then the generator cover will come off.

Yeah, I would hunt for a workshop manual too, like the others say, and give it a read before picking up the tools again. Take the problems one at a time and you should be OK.

The rotor does not look like its fragmenting. The lacquer is going out but otherwise its OK.
The air box cover missing will make it lean, not rich.

The flasher can be replaced by an electronic wagner 552, available at autozone types.
Cool.
Buddha.

Thanks for the replies 


Anyone had any experience with Loctite QuickMetal  660?
http://www2.blackwoods.com.au/infoBANKproduct.aspx?SG=2000165&S=19&G=2003508&P=2024824

Says it can handle temperatures up to 150 C , how hot does oil usually get?

Also do you think itd be the best thing to repair the hole in the rotor cover?


Had a look at a service manual, photo was sketchy but the air filter seems to face upwards. Never seen how it was on the gs but i always assumed the air intake would be facing forward so that air flowed in when youre riding? then again i have no idea  Oh well you live and you learn 

Cheers
Roshan

Air filters are not facing forward, in fact I have never see one that way. You actually dont want it forward facing cos it will take in all the rain and BS flying around in front of you. The GS has it facing back and up, and so do 90% of other bikes. Get that air box's right cover and fit it back on.

Oil will get to 150 and in case of having metal to metal contact like the rotor bolt it can get even hotter. Its connected to the crank, so it could well get to over 300 F. Dunno about that cover though, it can be JB welded though usually those fixes dont last too long IMHO.

Cool.
Buddha.

Thanks everyone.

Decided to just replace the stator cover and gasket. Ordering it in on tuesday, finally managed to actually get the cover off.

Also thanks buddah that wagner 552 flasher is exactly what i needed.

Oh btw what does it mean if the spark plugs are a nice brown colour and not too oily...yet the exhaust fumes smell really rich. sort of like uncombusted petrol?

Roshan