SuzukiSavage.com - Removing Left Side Engine Cover

Kenny G

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Re: Removing Left Side Engine Cover
Reply #15 - 11/17/16 at 05:45:47

Verslagen,

Thanks for the picture, the picture being worth a thousand words.

At this point I don't want to turn the engine over until I find the piece of broken aluminum. I will wait to finish pulling the cover until my gasket gets here.

I am familiar with checking to be certain that I am at TDC on the rockers before I attempt any adjustments.

Dave,

I wish I had known where to find the part number before I went to the dealer to order parts. We had a heck of a time finding the timing cover using the Suzuki Model Number(s).

Kenny G

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Dave

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Re: Removing Left Side Engine Cover
Reply #16 - 11/17/16 at 06:18:25

Kenny G wrote on 11/17/16 at 05:45:47:

Dave,

I wish I had known where to find the part number before I went to the dealer to order parts. We had a heck of a time finding the timing cover using the Suzuki Model Number(s).
Kenny G

It is listed in the Tech Section Table of Contents - But all you had to do was ask and one of the forum members could have directed you to the part numbers.
(There is a lot of information on this site if you know where to look).

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Kenny G

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Re: Removing Left Side Engine Cover
Reply #17 - 11/17/16 at 06:39:11

Dave,

I know this site is a treasure for owning a Savage/S40, but I guess I am not sure how to use some of the features to find information.

After I looked in the Technical Section it wasn't hard to find "Timing Cover Replacement" what could be more obvious?

As the saying goes: "There is no fool like an old fool". Thanks for being patient with some of us that are mechanically and information challenged.

Kenny G

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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Removing Left Side Engine Cover Reply #18 - 11/18/16 at 07:40:14 So far it looks like the most difficult part of this for me is going to be getting the springs off of the kick stand. I am not strong enough. Anyone have any tricks on how to pull the spring off? Kenny G :'(
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Re: Removing Left Side Engine Cover
Reply #19 - 11/18/16 at 07:44:38

Kenny G wrote on 11/18/16 at 07:40:14:

So far it looks like the most difficult part of this for me is going to be getting the springs off of the kick stand. I am not strong enough.

Anyone have any tricks on how to pull the spring off?

Kenny G :'(

I don't think you have to take it off? Doesn't it just come off with the footpeg mount?

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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Removing Left Side Engine Cover Reply #20 - 11/18/16 at 07:46:31 Kenny, don't mess with the springs. they come off with the mount.
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Removing Left Side Engine Cover Reply #21 - 11/18/16 at 07:51:47 Verslagen Thank You, Kenny G
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Kenny G

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Re: Removing Left Side Engine Cover
Reply #22 - 11/18/16 at 09:29:31

Verslagen,

Not having to remove the springs from the kickstand was a life saver.

I managed to get the left cover off and found the broken piece of aluminum and removed it.

Both locating dowels are intact and where they belong.

I did find a washer laying in the cover that looks like it probably goes on the axel that is pressed into the cover that a small gear near the starter goes onto. I will look over the exploded view in the parts fiche online. If anyone know where it goes please chime in.

I ordered 2 of the left side cover gaskets, just to be safe.
As always, when there are spare parts coming, I didn't damage the gasket.

Should I just clean the gasket and re-assemble using the old gasket?

Kenny G

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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Removing Left Side Engine Cover Reply #23 - 11/18/16 at 09:52:11 I'd reuse the gasket if it looks ok. Goes on the torque limiter gear.
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Kenny G

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Re: Removing Left Side Engine Cover
Reply #24 - 11/18/16 at 10:17:43

Verslagen,

Thank You!!!

I am very glad that I asked the question about the washer. Thank you again. The axel shown on the gear with the X over it is in my cover. Should I pull the axel from the cover and insert it in the gear or leave well enough alone?

Should I go ahead and adjust the valves now or should I re-assemble the cover and pegs and stuff?

Kenny G

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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Removing Left Side Engine Cover Reply #25 - 11/18/16 at 10:28:10 You're going find it easier to assemble if all the gears and axles are on the case side. At least that's the way I did it.
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Removing Left Side Engine Cover Reply #26 - 11/18/16 at 22:39:00 Finally I am ready to adjust the valves. Working on a Savage/S40 during the day without Verslagen online to bail me out would be like trying to race a BMW in the olden times without being able to contact Reg Pridmore. Ken Crash
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Kenny G

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Re: Removing Left Side Engine Cover
Reply #27 - 11/19/16 at 08:11:49

I was just checking as to the torque requirements for the bolts that run trough the engine and hold the peg brackets on.

Here is what I found in the technical section:
Engine
mounting No. 1 bolts and nuts 37.0 45.0 | 27.3 33.2
Engine
mounting No. 2 bolt 70.0 88.0 | 51.6 64.9
Engine
mounting No. 3 bolts and nuts 70.0 88.0 | 51.6 64.9
Engine
mounting No. 4 bolt and nut 70.0 88.0 | 51.6 64.9
Engine mounting No. 5 Allen
20.0 30.0 | 14.7 22.1

How does one know which number the trough bolts are?

Kenny G

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verslagen1

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Re: Removing Left Side Engine Cover
Reply #28 - 11/19/16 at 09:11:22

Kenny G wrote on 11/19/16 at 08:11:49:

I was just checking as to the torque requirements for the bolts that run trough the engine and hold the peg brackets on.

How does one know which number the trough bolts are?

Good question, although it might be in the SSM, clymers doesn't say.

So we're left up to logic.
Below I've grouped the torques and we can see there are 3 levels.
#5 says allen, so those are the allen bolts above and below the swingarm.
#1 are the lowest and the rest are the highest.
All of the frame bolts are the same size, 17mm nuts. So those are the highest inc. the footpegs.
The bolts at the top are smaller, 12mm nuts, so those are the #1's

Engine mounting No. 1 bolts and nuts
37.0 45.0 | 27.3 33.2

Engine mounting No. 2, No. 3, No. 4 bolt and nut
70.0 88.0 | 51.6 64.9

Engine mounting No. 5 Allen
20.0 30.0 | 14.7 22.1

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Kenny G

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Re: Removing Left Side Engine Cover
Reply #29 - 11/19/16 at 10:21:18

Verslagen,

Thank you very much.

Earlier I had taken a chance on the 27 Ft LB and double checked the degree of tightness with a breaker bar and the through bolts felt "Good & Tight".

I have never used a torque wrench before with the exception of the internal bolts on an engine and torqueing a head down. Suddenly I am risking breaking bolts off, old age is wonderful. Undecided

Kenny G

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