How to remove the engine casing for polishing

[Trajik2009]

Hi all,

I'll be trying this for the first time so I was just after some tips on how to remove the engine casing for polishing. I know you have to remove the bolts but is there any cables that have to be removed? I have the 2009 model. Your expert advises would be greatly appreciated. I will also be doing the front forks.

[gsxbarmy]

First off get yourself a couple of bits of cardboard about the size of each casing. As you remove each bolt, push a hole in the cardboard for it such that you can put the same bolt back in the hole it dame out of when refitting. Why? Because on some bolts there are oil captive washers and you need to refit these exactly where they come from.

See this article http://gsx1400owners.org/forum/index.php?topic=268.0

Ok let's cover the smaller RH casing first. This just unbolt, you may or may not get a couple of drops of oil out when you remove it but that's it. Really straight forward, unbolt and remove.

The LH (generator) casing is a little more involved. First remove the gearbox sprocket cover and disconnect the wire running to the alternator (through the casing - you'll see it when you remove the cover). Next undo all the bolts, using the cardboard (as above).

To remove the casing itself can take a bit of brute force as the magnets of the alternator (which is bolted into the casing itself) will try to hold the casing onto the engine. It will help here if you have a rubber mallet and a couple of small wedges.

First, tap gently around the casing to break the seal of the gasket. Next, holding the casing in both hands gently pull it away from the engine. If you have wedges, as the casing comes away, get another pair of hands to put them into the gap that starts to form. When the casing is about 5-6mm away from the engine, just look straight down along the top rear. You will see a small round peg which actually is the shaft for the starter gear. If that is starting to come away with the casing, use a small screwdriver to gently push it back into the engine. Continue then pulling the casing away and checking the shaft until the casing is off.

Now - if there is a clatter and the shaft together with the small starter cog comes away don't panic. Get a ratchet socket that fits the stator crankshaft nut, put the starter shaft in the small cog, and whilst gently pushing on the ratchet socket to turn the engine backwards, re-engage the small starter cog and spline. It literally only needs slight pressure and it will slot straight back in.

Refitting is a reversal if the above process, just mind your fingers when refitting the alternator casing as the magnets will pull it in quickly often catching just the end of fingers - you have been warned.

Do also use some blue loctite and torque the alternator retention bolts up correctly as there have been odd instances of them coming loose.

These threads supporting the above statements also worth a read before you start
http://gsx1400owners.org/forum/index.php?topic=222.0
http://gsx1400owners.org/forum/index.php?topic=2048.0


Hope that helps 

[Trajik2009]

Thanks for that mate. Do you know if there is a youtube video on this? It's my first time so I don't want to stuff anything up. lol 

[gsxbarmy]

Not that I'm aware of or can find, sorry (I assume you mean casing removal and not casing polishing)

In all honesty it's easier than it seems, I somehow doubt you'll stuff it up. If at any stage you get concerned, just post up here, we can all help!

One more thought - are you dropping the oil out before removing the casings? Whilst that would be advisable, it's not totally necessary so long as the bike is in its mainstand in a level surface. You might find a tad of oil drips out of the alternator casing - which could be a bit messy - but it can be done.

[Trajik2009]

Yeah, for the casing removal. All good mate, thanks for the boost in confidence. I'm going to try it in a week or so. I'll do before and after photo's if it all works out. 

It's good to know that everyone here is more than happy to give advise. I'm not looking at doing an oil just yet. I'll get 1 litre of oil to top up after I finish.

Thank you for your help mate. I'll be sure to keep you updated.

[gsxbarmy]

no worries, look forward to seeing the end result!

[Trajik2009]

Hi mate,

Here are some before and after shots

[Trajik2009]

More pictures

[Latetsorpa]

Hey Trajik. Nice job for a DIY. What hardware did you use for it as I intend to do the same on my covers.

And Barmy, thanks for the tutorial 

Cheers,
Seb