[Ilya Trushchenko]

I crashed my versys on a dirt road. It landed on the left side and the engine cover was smashed with a rock.
If i'm lucky, stator is not damaged. I can replace the cover (already ordered a new one and the gasket).
But a piece of the cover is missing and I think it's somewhere inside the engine.
Should I take the engine apart in order to check for the missing piece? Is it possible at all to do this on my own in the parking lot?

 

[moto4you]

" ... is it possible at all to do this on my own in the parking lot"?
I would say no, find a small garage space (friend) where you are able to leave the bike overnight. Nothing is worse than being in a pinch and where you have to roll out. Things go sideways, have a plan before draining the oil to remove the Alternator cover.

BTW, after my covers got busted, I invested into R&G covers, they go right over, and saved Hornet many times!
Stator site
Kawasaki Versys and ER-6 Left Hand Side Engine Case Cover - ECC0121BK
Clutch site
Kawasaki Versys and ER-6 Right Hand Side Engine Case Cover - ECC0121BK

 

[Ilya Trushchenko]

Thank you a lot @moto4you! According to the manual, in order to get rid of debris, I need to:
1) remove the oil pan and clean it
2) remove internal oil filter? and clean it
3) remove the oil screen and clean it
Do I get it right - versys has an external oil filter (which you replace while changing oil) and 2 more internal filters?

 

[Ilya Trushchenko]

BTW I forgot to order oil pan gasket... is it really necessary to replace it on a 3 year old bike when you remove an oil pan?

 

[jdrocks]

Should I take the engine apart in order to check for the missing piece? Is it possible at all to do this on my own in the parking lot?

you're just going to replace the cover, the missing piece is not inside the engine cases. do not remove the oil pan, it's not necessary.

this is a very simple job, and you can do it in the parking lot, no special tools required. caveats, couple different length fasteners, remember their location. the thin gauge stainless positioning dowels are easily damaged, exercise care. make sure the stator leads are sealed, otherwise you'll have an oil leak. if you are careful, you may be able to reuse the cover gasket, there is no OEM sealant.

easy job, maybe an hour, maybe less, depending

 

[Ilya Trushchenko]

@jdrocks there is definitely a piece of a cover missing. Do you think it could not get into the engine?

 

[jdrocks]

@jdrocks there is definitely a piece of a cover missing. Do you think it could not get into the engine?

either the missing piece(s) fell off on the ground, or you'll find them when you take the damaged cover off. those pieces are not inside the engine cases, relax.

if you don't have a lift, and are going to make this repair in the parking lot, get some suitable padding and carefully lay the bike down on the right side, you'll make the job much easier and faster.

clean everything up before assembly. i use locker on the stator bolts. lube the starter gear shaft at the blind pocket in the cover.

you'll find out that this is an easy job.

 

[Ilya Trushchenko]

@jdrocks thank you so much for the words of encouragement and for good advice!
Despite I'm happy I walked away from that crash with few bruises (gear did its job nicely!) I feel so embarrassed for what I did to my versys.
I hope I'll be able to fix her soon.
That's amazing how helpful and supporting members of this forum are!

 

[fasteddiecopeman]

I did what jdrocks recommended when I replaced the FIRST stator I replaced, in my '09. Laid it down on the right side so the oil didn't leak out, then went to work.

Good luck.

 

[Ilya Trushchenko]

@fasteddiecopeman @jdrocks I removed the cover, seems like stator is not damaged. Spent an hour removing leftovers of old gasket
The manual says

Apply liquid gasket to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount.

should I run to home depot tomorrow to find that liquid gasket or is it safe to skip this step?
Also

lube the starter gear shaft at the blind pocket in the cover.
you'll find out that this is an easy job.

which lube should I use? I only have wd-40, motor oil and the only thick lube I have is Motul 102984 Chain Paste, will it work?

 

[jdrocks]

@fasteddiecopeman @jdrocks I removed the cover, seems like stator is not damaged. Spent an hour removing leftovers of old gasket

should I run to home depot tomorrow to find that liquid gasket or is it safe to skip this step?
Also

which lube should I use? I only have wd-40, motor oil and the only thick lube I have is Motul 102984 Chain Paste, will it work?

you can't skip that step. liquid gasket is just another name for RTV silicon, pick up a squeeze tube of any name brand RTV at an automotive store, i use clear. you should also source a spray can of 3M adhesive remover so you can easily clean up any excess RTV from the engine case and your new cover. be sensible about how much RTV you use, i'd rather have a little more than a little less.

your new cover is clean and dry, just use a little motor oil at the end support pocket for the starter gear shaft.

do yourself a big favor, do not over torque the cover fasteners.

 

[Ilya Trushchenko]

Already assembled without the liquid gasket... if it ever leaks - will redo with RTV silicon.
3M adhesive remover - i wish I knew about it earlier
But thank you, will buy these in advance if I ever have to remove the cover again.
Replaced the cover. Used threadlocker where needed and a torque wrench. Added some oil (cheap shell 10w40) and started the engine. Weird noise was coming from the engine... it was barely noticeable but I've heard some clicking noise from upper part of it. Also idle rpm was lower than usual. Flushed the oil, replaced the oil filter, added Mobil-1 racing 4t -- this time when I started the engine there was no clicking sound and rpm were OK.
Thank you a lot for your help!