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General Category >> Rubber Side Down! >> Left side crank case cover
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Message started by eanon on 08/15/09 at 12:20:07

Title: Left side crank case cover
Post by eanon on 08/15/09 at 12:20:07

Clymers says: "To remove the cylinder head cover, first set engine to TDC to relieve pressure on the rocker arms."

Got the special three pronged tool, but I still can't get the timing inspection cover to budge. I'm just fouling it up. Any problems with just taking the whole left side cover off? Do I have to remove the drive pulley (in my case, sprocket) to remove the left side cover? Can i still set TDC with it off? (never gone into that side of the engine before....) :-?

Title: Re: Left side crank case cover
Post by Stimpy on 08/15/09 at 13:06:27

Of course you can find TDC w/o the left cover, in fact its even
easier that way, it has markings on your giro "T" that indicate TDC.

- drain oil
- loosen foot rest and gear lever
- remove front belt guard (just the guard, no belt/sprocket needed)
- remove all screws (8mm I think)
- WATCH OUT for your electric sensor (don't rip it)
- pull whole cover, IT HAS/IS a MAGNET,
so you will feel "resistance" as if you forgot
a screw but its just your giros magnet doing
what magnets do best :D

Here is a short guide I wrote w/all the steps
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1246924611

Good luck

Title: Re: Left side crank case cover
Post by eanon on 08/15/09 at 13:38:21

awesome. Thanks Stimpy.

Title: Re: Left side crank case cover
Post by verslagen1 on 08/15/09 at 14:18:38

One note of caution, get a gasket to reinstall.
quite a few have had trouble reinstalling and getting a leak.

Title: Re: Left side crank case cover
Post by Toymaker on 08/15/09 at 17:07:53

yep yep yep yep yep

Gasket...yep

Did I say Yep? ;)

Title: Re: Left side crank case cover
Post by eanon on 08/15/09 at 17:07:57

check. got a full set on delivery. should be here sometime next week.

Title: Re: Left side crank case cover
Post by Duane on 08/15/09 at 17:41:09

On setting TDC, what east easy way to know you are set right to check valves? Went to get clutch part today and had to order it. 3 to 5 days till I get it. My pipe is pretty blue up close to the piston. I have heard that it might indicate that my exhaust valve clearancew may be a little tight. So I thought why not check the valves while I wait. I figure I'll just spin the back tire in the air till I get it there, now how am I gonna know when I'm there?

Title: Re: Left side crank case cover
Post by verslagen1 on 08/15/09 at 18:26:18

Plenty of tips in the tech sect.
I just turn the crank until the intake valves open
then keep turning til TDC is indicated.
turn in the direction the wheels turn to go forward.

Title: Re: Left side crank case cover
Post by justin_o_guy2 on 08/15/09 at 22:24:44

The first few times I set the valves I pulled that plug. Now, I just get TDC( or close enough to it to not have any load on the valve rockers) by pulling the plug & turning the engine over till the wooden dowel tells me the piston is at the top & I feel of the lifters & I know Im not at the top of exhaust. These books are written for people who dont know how an engine works. Is not necessary to go along with every word of it.

I was working on a 460 ford, in a jet boat. The starter had stopped working, but I needed to get the distributor in, It was on compression on #6, so I lined it up & dropped it in. The guy who owned it was near apoplectic, but I assured him it would be okay. He insisted distributors were put in with #1 up on TDC.. Well, I told him I was cool with that & It would work, & it did, but that aint nowhere NEAR what the book says..

Title: Re: Left side crank case cover
Post by Phelonius on 08/16/09 at 09:12:09

Stick you finger down the spark plug hole and feel the Piston as it comes to TDC.
If you are like me, our finger won't fit. Use a slender dowel rod. Quarter inch or three eighths will work fine.
;D ;D ;D
Phelonius

Title: Re: Left side crank case cover
Post by eanon on 08/16/09 at 13:25:56

a long straw (yes, the one you drink with) works great with no chance of damage.

Title: Re: Left side crank case cover
Post by eanon on 08/16/09 at 13:32:53

this is a little off topic but I already had the thread started so,

Clutch basket removal. The darn thing just spins when I try to remove the nut. After some thinking, aha!, bike has to be in gear. (we all make stupid mistakes, right?) any easy way to remove the nut holding the basket without putting the bike in gear? OR Any easy way to put her in gear without reassembly? (remember, i couldn't get the timing plug cover off, so i have removed both side covers, and have already removed the tensioner and the cam shaft.) Got to love stupid mistakes. >:(

Title: Re: Left side crank case cover
Post by justin_o_guy2 on 08/16/09 at 14:57:30

I used an impact & going back together, I think it really made life better.

Title: Re: Left side crank case cover
Post by eanon on 08/16/09 at 14:57:36

well, in the process of trying to engage the clutch to get her in gear, i broke the clutch cam, again! >:( >:( >:( (part #23)
http://fiche.ronayers.com/Index.cfm/Module/Main/TypeID/26/Type/Motorcycle/MakeID/2/Make/Suzuki/YearID/38/Year/1997/ModelID/6345/Model/LS650P_SAVAGE/GroupID/261331/Group/CLUTCH
Dam that little piece. So while i'm waiting for a new one, maybe i can finish installing this new chain. It's a little harder than I thought it was going to be. Clymer's is not nearly as descriptive as I would like.....

any tips on getting the clutch basket off?

-frustrated

Title: Re: Left side crank case cover
Post by eanon on 08/16/09 at 14:58:29

impact, huh? don't have one but have a friend who might....

Title: Re: Left side crank case cover
Post by verslagen1 on 08/16/09 at 15:40:13

Impact helps, but those of us who are tool chalanged...

stick a penny inbetween the gears just like in the arcade where they restamp the penny with pictures it's gonna get stamped with a tooth.

Title: Re: Left side crank case cover
Post by serenity3743 on 08/17/09 at 13:37:16

4A4E4140412F0 wrote:

I remember removing the clutch some time ago. I reinstalled 2 of the 4 bolts which hold the springs on, then used a huge screwdriver as a lever placed diagnonally across those bolts to hold the clutch stationary while I loosed the big nut.

Title: Re: Left side crank case cover
Post by eanon on 08/18/09 at 13:15:21

"stick a penny inbetween the gears just like in the arcade where they restamp the penny with pictures it's gonna get stamped with a tooth."

yeah, I even have a piece of scrap aluminum, just like the "special tool" on the TMH CD. (very helpful Cd, if any doesn't have it....) Only problem is, when i try to loosen the clutch hub nut, the inside of the basket (compression plate and clutch sleeve hub) spins separate from the clutch plates and the actual "basket". Only reason I can see is cause it's not in gear. Then, of course, I broke the clutch cam trying to "manually" put it in gear (pull up on clutch arm, push shifter arm forward, and spin drive sprocket), so there's NO getting her in gear for at least a week. :-/

"I reinstalled 2 of the 4 bolts which hold the springs on, then used a huge screwdriver as a lever placed diagnonally across those bolts to hold the clutch stationary while I loosed the big nut."

Didn't foul up the screws or springs, huh? Might have to try that. Still trying to get a hold of my buddy with the impact....

Title: Re: Left side crank case cover
Post by serenity3743 on 08/18/09 at 13:53:28

[quote author=3F3B3435345A0 link=1250364007/15#17 date=1250626521"I reinstalled 2 of the 4 bolts which hold the springs on, then used a huge screwdriver as a lever placed diagnonally across those bolts to hold the clutch stationary while I loosed the big nut."

Didn't foul up the screws or springs, huh? Might have to try that. Still trying to get a hold of my buddy with the impact....[/quote]

I didn't put the springs back on, just the bolts. Just hand tight as I rcall, and it didn't mess them up.

Title: Re: Left side crank case cover
Post by eanon on 08/18/09 at 14:22:08

sounds good. will try.

just so I have it correct, clutch hub nut is right hand (normal) thread, and primary drive gear nut is left hand?

Title: Re: Left side crank case cover
Post by verslagen1 on 08/18/09 at 14:31:00

Primary is left correct (right?)

Title: Re: Left side crank case cover
Post by eanon on 08/18/09 at 15:47:58

ok, so I feel really stupid. granted, I'm not some mechanical guru, in fact, most of my wrenching experience is on the savage, but still.....

so serenity said to use the bolts as lever points. tried this. screwed all the way in, the bolts sit below the level of the clutch sleeve hub, so a screwdriver, placed horizontally across, does not reach them. I unscrewed the bolts half way so they would stick out far enough, but really didn't like the idea of applying pressure to the bolts like that (images of fouled threads and bent bolts kept popping into my head.)

so, I found 4 washers. od big enough to cover the springs and id big enough for the bolts to go through. put the springs back on (no pressure plate) washers, then bolts. tightened everything up, and viola! clutch engages primary driven gear which engages primary drive gear and I can use the special tool (scrap alum) to hold everything in place! clutch basket and plates removed! Now back to advanced auto to get a 30mm sprocket.

i really should start getting all the tools needed before starting a job.......