SuzukiSavage.com - Right side engine cover removal

VOLKY YaBB Newbies Offline 2006 S-40 Boulevard Posts: 49 Florida Gender:	Right side engine cover removal 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?
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MotoBuddha

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Re: Right side engine cover removal
Reply #1 - 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.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Right side engine cover removal Reply #2 - 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.
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jandaso Full Member Offline Do you want fries with that? Posts: 145	Re: Right side engine cover removal Reply #3 - 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.
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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Right side engine cover removal Reply #4 - 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
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VOLKY YaBB Newbies Offline 2006 S-40 Boulevard Posts: 49 Florida Gender:	Re: Right side engine cover removal Reply #5 - 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?
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Right side engine cover removal Reply #6 - 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.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Right side engine cover removal Reply #7 - 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.
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Boofer

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Re: Right side engine cover removal
Reply #8 - 11/03/11 at 21:10:32

VOLKY wrote 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?

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.

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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Right side engine cover removal Reply #9 - 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.
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kuri77

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Re: Right side engine cover removal
Reply #10 - 11/04/11 at 00:00:57

justin_o_guy2 wrote 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.

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.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Right side engine cover removal Reply #11 - 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.
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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Right side engine cover removal Reply #12 - 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.
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