Right, sooooo a little clarification?

Picture of what cover i was talking about:



gasket i think it is: http://www.bikebandit.com/oem-parts/2002-suzuki-savage-650-ls650p/o/m147696#s... part 11


we got the cover mostly off but stopped. we did take the long bolts out that held the pegs and the front of the engine on, but it looked like we'd need to take the kick stand and what not fully off to get the cover off. after putting it back together it leaks a bit less.


are we going in the right direction?

Is that side cover damaged?

not visibility

Did you get it apart far enough to see if the gasket was torn?

no, we did not get the cover more then about half an inch off.


Did you manage to aply a thin film of sealer

no

Well.....your a little late seeking our advice,you should have tried tighting the through bolts that hold the pegs first,then the rest of the bolts holding the cover. but now you've moved the cover and may have torn the gasket ,you/ll have to get it off now and replace it after cleaning the surfaces,you may have to remove all the motor mounting bolts ,exhaust ,dive belt ,speedo cable, clutch cable, so you can lean the motor over to have room to pull the cover,or maybe just remove the side stand,don't know haven't been there.

justin_o_guy2 wrote on 07/18/16 at 20:26:34:


Most likely....they only got the cover off 1/2" because they didn't do anything to loosen the clip that holds the wiring in place behind the pulley.

There is only one way to fix this now, and that is to loosen the wiring harness, take the cover off, remove the old gasket and clean up everything, install a new gasket, and put it back together properly.

Hi, I'm the friend with the garage.

This seemed like a pretty straightforward question, I'm not sure why this forum is so hostile and assuming that we're incompetent. The bike was leaking oil, it seemed to be coming from behind the sprocket cover so we pulled it. After that, it was pretty obvious the crankcase cover was leaking. Since we knew we'd be replacing the gasket entirely at some point, we figured we'd open it up and see how difficult it was while we were there.

Surprisingly, Dave, we noticed the wiring harness bolt and removed it and the wiring there was freed.

We started late in the day, so once it was obvious that the gasket needed replacing and that we'd have to do anything more than just unbolt the cover, we buttoned it back up, added oil, rode it half an hour and checked the oil to make sure it would be fine for a while (it was), and ordered the gasket. Certainly not permanent, but good enough to ride until the part ships.

So, Dave, you pointed out that we'd need to remove the cover, clean up, and replace the gasket. Since that's exactly what we set out to do in the first place, can you tell us if we need to remove the engine from the bike to do it?

Batman, you just mentioned washers on the correct starting gears. Care to elaborate on that? Are these washers actually held on by the case? Is there any reason we'd remove them if not?

Verslagan1 thanks for the mention of the magnets- that explains how the cover was moving on us.

guffikins wrote on 07/19/16 at 10:15:28:

To paraphrase an old joke...
How do you piss off a lot of people trying to be helpful?

Tell you tomorrow...

Dave wrote on 07/19/16 at 10:34:29:



yea sorry i posted, went to sleep, then couldn't post at work.