SuzukiSavage.com - Removing Left Side Engine Cover

Kenny G

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Removing Left Side Engine Cover
11/16/16 at 10:41:07

While getting ready to adjust my valves I broke a piece off of the backside of the threaded inspection cover. Naturally the broken piece fell in the inspection hole and I could see it. When I went to pickup the broken piece with a tweezers it fell into the engine.

I have all of the bolts removed from the left side engine cover. Before I attempt to pull the cover what else do I have to remove from the engine to find the missing piece of aluminum?

All help will be appreciated.

Kenny G :'(

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Dave

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Re: Removing Left Side Engine Cover
Reply #1 - 11/16/16 at 11:17:45

The wiring harness comes out the backside of this cover, and it is held in place by a sheet metal shield that is held on by a single screw. You need to remove this shield to allow the wires to come forward with the cover.

And when you go to pull the cover off - it will move and then feel like somebody is pulling it back on! The strong magnets make a "tug or war" out of the process. You likely will need a new gasket, as they tend to tear.

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Kenny G

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Re: Removing Left Side Engine Cover
Reply #2 - 11/16/16 at 11:48:23

Thank you Dave,

I am thinking you are telling me that I will have to remove the guard covering the belt pulley to get at the sheet metal screw to remove the sheet metal shield to allow the wires to move?

Will the cover clear the foot peg and side stand when I attempt to pull it off?

I am a little dense when it comes to mechanical stuff.

Kenny G Undecided

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Dave

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Re: Removing Left Side Engine Cover
Reply #3 - 11/16/16 at 11:55:15

Kenny G wrote on 11/16/16 at 11:48:23:

I am thinking you are telling me that I will have to remove the guard covering the belt pulley to get at the sheet metal screw to remove the sheet metal shield to allow the wires to move?

Will the cover clear the foot peg and side stand when I attempt to pull it off?

Kenny G Undecided

You will have to remove the pulley cover/guard, and you may also have to loosen/remove some plastic ties that hold the wiring harness to the frame. Be careful to get it back together properly - more than one member has not got the wiring harness back properly and the belt has rubbed through the wires and left them "stranded" (pun intended).

I have not removed a left cover on a bike with stock footpegs/sidestand in a long time.....I don't remember if the peg assembly needs to be removed.

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verslagen1

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Re: Removing Left Side Engine Cover
Reply #4 - 11/16/16 at 11:58:14

Kenny G wrote on 11/16/16 at 11:48:23:

I am thinking you are telling me that I will have to remove the guard covering the belt pulley to get at the sheet metal screw to remove the sheet metal shield to allow the wires to move?

Yes, you need to remove the pulley cover
Quote:

Will the cover clear the foot peg and side stand when I attempt to pull it off?

No, you will need to remove both.

I'm not sure if the wiring comes off with the cover. You'll see it better when you take off the pulley cover. There's a rubber bit that the wires pass thru. And I think it's on the case side like the neutral wires on the clutch side.

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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 #5 - 11/16/16 at 12:08:52 Dave & Verslagen Thanks for information. I am going to go to the cycle store and order the gasket and a timing cover from an Intruder that I will need, and then I will finish disassembly. Wish me luck. Kenny
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DavidP YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 45	Re: Removing Left Side Engine Cover Reply #6 - 11/16/16 at 12:51:01 Is it a big piece? I am wondering if it might flush out if you were to drain the oil. Drain it through an old pair of tights or similar and you would know if you caught it. DavidP
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Steve H Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1223 Spartanburg, SC Gender:	Re: Removing Left Side Engine Cover Reply #7 - 11/16/16 at 15:07:49 You do need to move the footpeg mount to get the stator cover off IIRC. The gasket has a couple of preglued spots on it to make sure it will disintegrate when removed. If you remove the wiring, make sure the rubber block seats well when you put it back together or it will leak oil.
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youzguyz

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Re: Removing Left Side Engine Cover
Reply #8 - 11/16/16 at 15:48:05

The wiring comes off with the cover (the rubber plug is in the cover, not on the engine case).
As said before, makes sure you take off that single screw/bracket that holds the wire harness to the case, and loosen those plastic wire ties.
While you CAN let the cover dangle by the wiring, you may need to get it completely off so you can clean up the mating surfaces a bit easier.. and that is also the best reason for getting the foot peg completely out of the way.

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Kenny G

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Re: Removing Left Side Engine Cover
Reply #9 - 11/16/16 at 17:52:21

Thanks Guyz & Steve & David,

I was able to find the correct part number for the timing cover with the hex rather than the slotted cover. The hex is Suzuki Part# 09259-36008 it is available from Ron Ayers $10.62 or my local dealer for $15.95 + tax.
I want to post the part number in the Technical Area.

I should have the parts that I need by Friday or Saturday.

Kenny G

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Removing Left Side Engine Cover Reply #10 - 11/16/16 at 20:15:23 I'm not sure ,but you might try taking a small piece of a magnet (Like the kind that you stick on the frig ) on a piece of fishing line and see if you can retrieve the invaders before pulling the cover .
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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 #11 - 11/16/16 at 20:18:23 BatMan, I could get it with a magnet, but the piece that fell in is aluminum. Lousy day for bad luck...I will get over it. Kenny G
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Kenny G

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Re: Removing Left Side Engine Cover
Reply #12 - 11/16/16 at 22:32:55

I am having trouble finding the reference marks to find TDC as mentioned in Clymer's.

"Align the groove on the end of the alternator rotor with the notch in the alternator cover".

I have found a yellow dot on the rotor and there is a small dab of blue paint on the cover by the threads for the inspection cover.

I am using Verslagen's post for the valve adjustment.

Kenny G Undecided

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Removing Left Side Engine Cover Reply #13 - 11/16/16 at 22:44:45 You'll find the mark on the cover at 3 o'clock. the mark on the crank is probably under the paint. it's a deep scribe mark that radiates out from under the nut.
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Dave

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Re: Removing Left Side Engine Cover
Reply #14 - 11/17/16 at 04:13:10

Kenny G wrote on 11/16/16 at 17:52:21:

I was able to find the correct part number for the timing cover with the hex rather than the slotted cover. The hex is Suzuki Part# 09259-36008 it is available from Ron Ayers $10.62 or my local dealer for $15.95 + tax.
I want to post the part number in the Technical Area.

Kenny G

The part numbers are already in the Tech Section.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1416070003

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