05-23-2013, 11:03 PM
(05-23-2013, 07:54 PM)RonLyke_imp Wrote: Let's pretend I did the same thing----
What's involved in changing the crankcase cover (left side)?
When it's removed, would I lose all the oil?.....Loose parts to fall out?....difficult things to align/fit when replacing?
Of course, this is just hypothetical...I would never do such a thing.
I hope this isn't considered hijacking the thread; if so, please delete.
Thanks in advance.
Yes for me it is the left side, the parts website calls it the left crankcase cover, in the manual it says Alternator Cover in the Alternator/Clucth section. If you don't have the service manual already I would recommend getting one whenever you have some extra cash, it has a ton of info.
I hope I am not breaking any copy right laws by typing this stuff up from what I learned but, you are supposed to start off by removing the side cover and starter motor...
I'm not sure if the starter motor is really in the way? Maybe it is for the alternator wire, because after removing these two items you have to remove the alternator wire from all the guides and clamps.
The manual says engine oil will run out if the alternator cover is removed, so if I do decide to do this I'll be performing it with an oil change and drain it before attempting to remove the cover.
I don't think the parts should be loose, but after removing the starter reduction cover and O-ring (will need a new O-ring, per manual) the gear shaft and starter reduction gear will need to be removed. Once done you can remove all the bolts and alternator cover (the manual has a note saying the stator is magnetically attracted to the flywheel and to be careful)
Once the cover is off, the alternator wire can be disconnected from the stator after removing its bolt and clamp and the stator can be removed after taking out its 4 bolts that will need to be torqued down to 9lbf-ft
To put it back together you would need to apply sealant (three bond 1207B) to the alternator wire grommet and torque the mounting bolt to 9lbf-ft as well
Also need sealant on the "mating surfaces" of the crankcase and alternator cover.
It specifies to tighten the bolts on the cover in a "crisscross pattern" (no torque spec)
and to put oil on the starter reduction gear, gear shaft and new O-ring.
Install the starter reduction cover and from here all you will have left to do is secure the wire and installing the starter motor and side cover.
If I do decide to go through with it (I think I will in a few months [after I get crashbars]) I'll turn this into a "How To"... unless somebody who also has a few scratches on theirs already... beats me to it

and I'll include plenty of my own pics.

