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I cannot get the generator cover off. What am I missing?

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Hi Folks,

I cannot get the generator (magneto, gear lever side, L/H side etc) cover off my DRZ.

I have removed, as per the Suzuki workshop manual, -

(Sprocket cover already off)

The gear shifter.

The two hex-head covers off the main casing.

The starter gear cover.

The starter gear.

ALL the casing bolts (I'm sure of this, as I have dropped them into their holes on the replacement casing I'm attempting to fit).

The case will come away a small amount everywhere except at the starter motor. Do I need to remove the starter motor? The manual doesn't say and it seems the casing should slide off the starter as easily as the starter would slide out of the casing?

If I do, do I really have to remove the tank, panels, exhaust etc (it appears so)?

Any advice mush appreciated. Someone must've done this many times before :)

Ta.

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gen_cover.jpg

The cover is held on by 7 fasteners.. One is behind the starter gear and cover. There are also two dowel pins that can make the cover a bit difficult to remove. Remove all 7 fasteners,, then evenly lift the cover off.

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Thanks for the reply. I've already got all the fasteners (inc the one behind the starter gear).

I know it has a couple of locator dowels, but this case is really not moving around the starter motor area.

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Hi Folks,

I cannot get the generator (magneto, gear lever side, L/H side etc) cover off my DRZ.

I have removed, as per the Suzuki workshop manual, -

(Sprocket cover already off)

The gear shifter.

The two hex-head covers off the main casing.

The starter gear cover.

The starter gear.

ALL the casing bolts (I'm sure of this, as I have dropped them into their holes on the replacement casing I'm attempting to fit).

The case will come away a small amount everywhere except at the starter motor. Do I need to remove the starter motor? The manual doesn't say and it seems the casing should slide off the starter as easily as the starter would slide out of the casing?

If I do, do I really have to remove the tank, panels, exhaust etc (it appears so)?

Any advice mush appreciated. Someone must've done this many times before :)

Ta.

What are you trying to remove???? The Generator cover????? or the left side case cover?

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I'll try loosening the two starter mounts, cheers.

It is the cover in the pic you posted I'm trying to remove. I stuck the shifter lever through it in an off.

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I'll try loosening the two starter mounts, cheers.

It is the cover in the pic you posted I'm trying to remove.

The starter is fit to back side of that cover by way of an oring.. Then bolted down to the motor.. It can bind a bit. As burned said,, loosen the starter bolts,, to give it some free play.. The cover should come right off :)

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Thanks for the advice.

I've had to put it away for now as it's dark here in about an hour.

I'll give it a go in the morning. Ta :) .

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The mag cover was touch for me to take off due to the magnetism in the magneto. The magnets just wanted to keep the cover in place.

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I was going to say. Keep working at it, the magnets hold the thing on pretty tight.

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Mine was tough to get off too. If it comes away some, it must be the magent holding it in. If it's really stuck, there are machine screws to remove inside the starter gear housing. Are you sure it's coming off part of the way all the way around?

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All sorted and running again after nearly 3 months in the shed :) .

It was the starter O-ring being stubborn.

Thanks very much for the help folks, seriously :) .

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