Can't get my engine cover back on! 2011 DL650 - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
DL650 and DL650A - 2004 to 2011 DL650 from 2004-2006 (K4-K6) and DL650 or DL650A from 2007-2011 (K7-L1)

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post #1 of 11 Old 05-13-2019, 09:46 PM Thread Starter
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Can't get my engine cover back on! 2011 DL650

Hello everyone. My poor bike has been apart for weeks now and I finally got all my parts today. I excitedly installed my new stator but for the life of me cannot get my engine cover back on. I've attached a picture but it seems to be hitting right where I've circled.

Whats the trick? Thanks!
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post #2 of 11 Old 05-13-2019, 10:11 PM
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Is the pull of the magnets tugging the cover to one side?
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post #3 of 11 Old 05-13-2019, 10:19 PM Thread Starter
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I can definitely feel the magnets pulling, but I think I'm managing to go straight. I can get the cover on this far before it hits something and stops.
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post #4 of 11 Old 05-13-2019, 10:28 PM
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I had this same issue two days ago. That guide rod that you have circled is fitted into a loose gear cog and is very easily knocked out of position.

It takes a few attempts but it will fit correctly with perseverance.

There are two guide sleeves on two of the retaining bolts as well. One top and one bottom. I used them as a guide to ensure I was on the correct angle.

My new stator arrives tomorrow so I have to deal with the same issue all over again in a day or two as well.

Good luck

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post #5 of 11 Old 05-13-2019, 10:30 PM Thread Starter
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Thanks for the reply! I was a little worried about that loose gear, thinking it somehow came out. I've tried manipulating it, is there a trick? What's the correct position?
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post #6 of 11 Old 05-13-2019, 10:32 PM
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I sent a pm, but back that pin out some and use it as a guide. The magnets pull is less further out. That should let you line things up enough to get things together.


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post #7 of 11 Old 05-13-2019, 10:37 PM
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Push the rod you have circled as far into the casing as it allows you and then make sure the cogs teeth are lined up correctly with the cog that it aligns with to the left.

I then held the engine cover in both hands but gripped the rod you highlighted between my index and middle finger so I could guide it into the corresponding hole on the back side of the engine case.

Slowly pushing the cover on bit by bit and making sure that the other guide sleeves on the two retaining bolts are aligned correctly.

Also, the stator has a small black conduit that needs screwing into the back side of the cover, if you have accidentally put the metal base on the wrong way round that may screw with your clearance so double check it's right before you go any further.

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post #8 of 11 Old 05-13-2019, 11:07 PM Thread Starter
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Quote:
Originally Posted by Thebigdog4 View Post
Push the rod you have circled as far into the casing as it allows you and then make sure the cogs teeth are lined up correctly with the cog that it aligns with to the left.

I then held the engine cover in both hands but gripped the rod you highlighted between my index and middle finger so I could guide it into the corresponding hole on the back side of the engine case.

Slowly pushing the cover on bit by bit and making sure that the other guide sleeves on the two retaining bolts are aligned correctly.

Also, the stator has a small black conduit that needs screwing into the back side of the cover, if you have accidentally put the metal base on the wrong way round that may screw with your clearance so double check it's right before you go any further.

Sent from my H3113 using Tapatalk

I'll double check the metal base and use the technique you described. Thanks!
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post #9 of 11 Old 05-13-2019, 11:33 PM Thread Starter
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Turns out I had that metal base for the black electrical conduit on correctly but had routed the wires coming off the stator incorrectly and that must have been the problem! Thanks so much for everyone's input! Cover is back on and tightened all bolts to 10nM. Thanks again!
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post #10 of 11 Old 05-14-2019, 08:50 PM
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This is timely. I got my replacement stator today. Hope to get it installed this weekend. Thanks for the pictures. Helps bring back memories from 32k miles ago.
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