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General Category >> Rubber Side Down! >> Right side engine cover removal
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Message started by VOLKY on 11/03/11 at 16:50:54

Title: Right side engine cover removal
Post by VOLKY on 11/03/11 at 16:50:54

Does anyone knows how to remove the right side (oil filter side) engine cover? I want to remove it since it is heavily pitted and want to polished. I know i need to remove the filter, exhaust heat shield, and all the bolts. What about the clutch lever?

Title: Re: Right side engine cover removal
Post by MotoBuddha on 11/03/11 at 16:57:55

Just drain the oil and unbolt. You'll probably need a new gasket since it will probably tear, with bits left on both the cover and crankcase. Watch to make sure the small rod in the middle of the clutch assembly doesn't fall out and get lost. There are slots in the crankcase, under the clutch, that you'll want to block off while the cover is off so things don't fall in.

Title: Re: Right side engine cover removal
Post by justin_o_guy2 on 11/03/11 at 17:26:13

Pay attention to where each bolt comes from. I used cardboard with X slots to keep each bolt located on a diagram of the side cover.

Title: Re: Right side engine cover removal
Post by jandaso on 11/03/11 at 17:38:34

If I'm not mistaken. There is one long one and 3 with whashers. They need to go to the same place you got them out.

Title: Re: Right side engine cover removal
Post by verslagen1 on 11/03/11 at 19:01:42

while you're in there check the cam chain...

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1191167029

Title: Re: Right side engine cover removal
Post by VOLKY on 11/03/11 at 19:23:50

I already have a new gasket, so I will use the new gasket and put the bolts were they go.

My question is the clutch lever that is at the rear of the cover. Does it have to come out before removing the cover? Or comes out with the cover?

Title: Re: Right side engine cover removal
Post by MotoBuddha on 11/03/11 at 19:27:48

No. In fact, you can't remove that lever without taking the cover off. There's a cotter pin holding it.

Title: Re: Right side engine cover removal
Post by justin_o_guy2 on 11/03/11 at 19:47:52

If you dont hold the loop up the cable goes in while you bolt it back on, youre gonna be whining.

Title: Re: Right side engine cover removal
Post by Boofer on 11/03/11 at 21:10:32

4C55565143565B545E3A0 wrote:

I took a sharpie and traced the gasket complete with bolt holes onto the cardboard the gasket came with. I just did the head cap and timing chain adjuster. I put a dab of rtv sealer under the head of all my bolts, even the ones with out washers. Suzuki mechanics recommend no gasket sealer, but I did use a few dabs to hold it in place where it kept falling off. Take a crescent wrench and put it at the pivot point on the clutch lever pushing down to relieve the pressure on the clutch cable. Bend the little tab back first, but don't worry if it breaks. A cotter pin can be used to replace it. Don't let the pin fall out of the center of the clutch.

Title: Re: Right side engine cover removal
Post by verslagen1 on 11/03/11 at 21:56:57

There ain't much of a trick to it.
only 2 bolts are long, fore and aft.
all the others are the same size.
as for the 3 washers, the aft one goes above the long one in back
the front pair go in front of the lower oil port, one above the other.

Title: Re: Right side engine cover removal
Post by kuri77 on 11/04/11 at 00:00:57

637C7A7D60675666566E7C703B090 wrote:

If you dont hold the loop up the cable goes in while you bolt it back on, youre gonna be whining.

I think I just experienced that when I did the Verslavy. The lever was below horizontal so that after I bolted on the cover there wasn't enough room to raise the lever to put the clutch cable back in because it was hitting the case. That what you meant? Of course I thought I had to take the whole cover off but by backing the bolts out a little I managed to do it without removing the cover again.

Title: Re: Right side engine cover removal
Post by justin_o_guy2 on 11/04/11 at 04:57:47

Yea,, thats the Bear TRap,, It doesnt rip a foot off, but I dont like creating a hassle, so I thot Id warn the guy.

Title: Re: Right side engine cover removal
Post by verslagen1 on 11/04/11 at 08:16:30

Not really an issue, while you are operating that lever to attach the cable, just use the other hand to swing the U shaped clip around to the correct orientation. You don't have to remove nothing.