UH-OH!! What'd I do wrong now? Transmission cover question

[newvined]

Hey guys,
I was working to replace a seal on the transmission cover. (by the way its an 82 gs850L) I had a local repair guy who only works on these old bikes tell me thats probably where my leak is.

(Its definitely on that side of the bike. Oil sending unit is good, and its a low leak meaning from the lower end of the engine, and on the tranny side for sure.).

He told me to take the cover off and replace that seal. So I started to. The bike was in neutral. I removed the bolts, and had to lightly tap the cover with a rubber mallet to loosen it up.

Now that the cover is free I can see it has a cable attached to it. (clutch cable I assume), and one of the gears wants to come out as well. It seems to be attached to the cover.

Too late to turn back now, but can't seem to get enough room to get to the cable and gear.

Is there anything I can do that won't involve spending big $$. Should I have had the bike in gear? I'm certainly not an expert but I am not sure where I went wrong? (That explains the JR. member status

Thanks in advance,
David Newvine
3 1982 GS850L's
What was I thinking??!!??

[Nessism]

Are you working on the right side of the engine or the left (as viewed if you are sitting on the bike)? The clutch cover is on the right, and the stator cover is on the left. If you removed the stator cover the starter gear will try to fall off and there is a wire harness for the stator that will keep you from removing the cover until the wires are freed. If you are pulling the clutch cover the clutch release mechanism is built into the cover. Not sure if this is the gear you are refering to. At any rate, I don't understand what the problem is so please provide more detailed information.

[twr1776]

Not sure if I am understanding which cover you are removing either. Are you working on # 15 ?

http://www.flatoutmotorcycles.com/fiche_image_popup.asp?fveh=2145&section=95343&year=1982&make=Suzuki&category=Motorcycles&dc=1620&name=CRANKCASE+COVER

[newvined]

Are you working on the right side of the engine or the left (as viewed if you are sitting on the bike)? The clutch cover is on the right, and the stator cover is on the left. If you removed the stator cover the starter gear will try to fall off and there is a wire harness for the stator that will keep you from removing the cover until the wires are freed. If you are pulling the clutch cover the clutch release mechanism is built into the cover. Not sure if this is the gear you are refering to. At any rate, I don't understand what the problem is so please provide more detailed information.

Nessism,
Sorry I wasn't clear enough the first time.

yes it it the left side so it must be this stator you have described. The wire is attached to this part (stator cover) and a gear wants to come out with it. So I need to know how to free those wires, and what do I do about that gear?

Thanks for the help
David

[newvined]

Not sure if I am understanding which cover you are removing either. Are you working on # 15 ?

http://www.flatoutmotorcycles.com/fi...RANKCASE+COVER

yes it is #15. I didn't know what to call it.

Thanks,
David

[Mr. Brown]

The stator is attached to the inside of the cover. The wires attached to the stator feed through a hole in the stator cavity into the area with the starter motor, and up to a connection near the battery. I don't think you can replace the gasket w/o disconnecting the stator. So...

-) Remove the two 8mm bolts that hold down the cover over the starter motor.
-) Follow the stator wires up to where they connect in front of the battery. There are three bullet connectors at the end. Unplug them.
-) Pull the stator wires out thorough their hole.
-) Now you can remove the whole stator cover. Be sure you remember which bolts go where, as they are different sizes, and getting them wrong will cause you to drip.

Be sure to clean off all the old gasket. I learned to be very careful and not scratch the aluminum. I like to (carefully) use gasket removal spray as it gets things off cleanly with no damage to the mating face. You just can't get it on anything else.

Put the new gasket on, feed the wires back through, and reconnect them. It doesn't matter which goes where. Reinstall the starter motor cover, and bolt your stator cover back on.

I would encourage you to get a manual for your bike ASAP. They aren't hard to find, and sure come in handy. Mine is greasy, folded, and written in.

Good luck!
-=T=-

[BassCliff]

Hi Mr. newvined,

The stator removal/replacement is documented on my website. Please help yourself.


Thank you for your indulgence,

BassCliff