Generator Cover Removal - Kawasaki Versys Forum
 
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post #1 of 8 (permalink) Old 07-05-2009, 11:48 AM Thread Starter
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Generator Cover Removal *Solved*

I got a replacement generator cover since I ground mine up pretty good in my spill. What is behind it ? I don't have a service manual and was going to tinker in the garage today. Can I replace it without draining the oil ? Are there strange springs going to fly out and land in inconspicuous places in my garage ?

Yes, I need a good manual. I couldn't find it in the online service manual. I suppose whilst I wait for the combined knowledge of your responses I'll look at the diagram at bike bandit.

Thanks in advance for any insight!

UPDATE: It _is_ in the manual. Page 516. I was looking for "generator" instead of "alternator". Thanks to Machog!

Last edited by cetzel; 07-05-2009 at 12:03 PM. Reason: Solved
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post #2 of 8 (permalink) Old 07-05-2009, 11:53 AM
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Photo's won't copy from the manual, but here are the 'words'. If 'words' alone aren't enough, PM me and I might have a better idea.

Machog

Alternator Cover Removal •Remove the lower fairing (see Lower Fairing Removal in
the Frame chapter). •Disconnect the alternator lead connector [A].
•Place a suitable container under the alternator cover [A]. •Remove:
Alternator Cover Bolts [B]
Clamp [C]
Bracket [D] •Pull the alternator cover outside.
Alternator Cover Installation •Apply silicone sealant to the alternator lead grommet and
crankcase halves mating surface [A] on the front and rear
sides of the cover mount.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
•Check that dowel pins [B] are in place on the crankcase. •Install a new gasket and the alternator cover. •Tighten:
Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Stator Coil Removal •Remove:
Alternator Cover (see Alternator Cover Removal)
Holding Plate Bolt [A] and Plate
Alternator Lead Grommet [B]
Stator Coil Bolts [C] •Remove the stator coil [D] from the alternator cover.


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post #3 of 8 (permalink) Old 07-05-2009, 11:56 AM Thread Starter
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Machdog, thanks! Is this from one of the manuals we can download from the forum links ?
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post #4 of 8 (permalink) Old 07-05-2009, 11:59 AM Thread Starter
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Quote:
Originally Posted by cetzel View Post
Machdog, thanks! Is this from one of the manuals we can download from the forum links ?
Spelling Correction: Machog. Man my dyslexia is working good today. Perhaps I should put the wrenches down.
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post #5 of 8 (permalink) Old 07-05-2009, 12:09 PM
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Yep, that's it.

Machog


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post #6 of 8 (permalink) Old 07-05-2009, 02:24 PM
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Manual mentions: "Place a suitable container under the alternator cover [A]" to catch spilling oil when removing the cover... Oil won't spill if you lean the bike enough to the right.

Last edited by invader; 07-05-2009 at 06:09 PM.
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post #7 of 8 (permalink) Old 07-05-2009, 07:30 PM
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Hi Cetzel,

If you need the manuals, try http://www.kawasakiversys.com/forums...hlight=manuals

Best Regards.

My V Blog:
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Ride safe,
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post #8 of 8 (permalink) Old 07-06-2009, 12:59 AM
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You might be able to leave the original undamaged gasket on the case by carefully removing the cover, and seal it back up with a touch of silicone sealant after wiping off any oil, like I did with my clutch/crankshaft sensor cover gasket. Gasket may be well stuck on the engine casing, which is hard to completely clean off without gouging the aluminum and creating a leak... I also removed my Yamaha WR426's generator cover a few times without replacing gasket or adding any silicone sealant, and without dripping any oil by leaning it to the right.

Last edited by invader; 07-07-2009 at 04:14 AM.
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