Generator Cover Torque - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 6 Old 04-03-2019, 11:25 AM Thread Starter
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Generator Cover Torque

I recently had to pull the generator cover off because someone used JB Weld on the plug ($%*@). I am now re-installing and looking for torque specs and tightening pattern for the generator cover. Does any one know where to find this? As best I can tell it is not in the shop manual (04 1000DL).
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post #2 of 6 Old 04-03-2019, 11:45 AM
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Look in your service manual for the generic bolt torque spec if it's not in the exploded view of the item being torqued.
For example, in my '14 DL1000 Suzuki Service Manual this chart is found in the Service Data section and gives bolt torque for the specific thread diameter and bolt hardness as marked on the head of the bolt.
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post #3 of 6 Old 04-03-2019, 12:31 PM
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Quote:
Originally Posted by Antibus View Post
I recently had to pull the generator cover off because someone used JB Weld on the plug ($%*@). I am now re-installing and looking for torque specs and tightening pattern for the generator cover. Does any one know where to find this? As best I can tell it is not in the shop manual (04 1000DL).
I don't know if by "shop manual" you meant Suzuki's specific manual covering your year & model, or if you were referring to a Chilton, Haynes or some other manual.
At the risk of misleading you, here's some things I found in my official Suzuki DL650A Service Manual covering 2017. I would be very surprised if the official manuals are laid out noticeably different; which chapters follow which, IOW.
In the beginning Service Data chapter, 0c-12, is a section on fasteners, and they list torques for various sizes and types of fasteners. I think the other manuals have similar info.
In Chapter 1J, they discuss the Charging System, and the procedure to remove/install the generator cover starts on page 1J-7. It says to tighten the generator cover bolts to 10 Newton meters or 7.5 lb ft. It doesn't show a tightening sequence, but my rule-of-thumb is to lightly torque the bolts opposite each other then follow up tightening in the same pattern to the specified torque. It also says to install a new generator cover gasket.

IMHO, I would think that there is little if any difference in this type of non-load bearing part between the 650 and the 1000, and I personally would be OK with using that figure; not much more than finger tight anyway. But you do what you wish with this.

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post #4 of 6 Old 04-03-2019, 02:19 PM
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Here ya go:
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File Type: jpg Torque.JPG (97.3 KB, 4 views)
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post #5 of 6 Old 04-03-2019, 03:51 PM
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You can use a torque wrench if you like, but I wouldn't. The spec is only 8.0 lb-ft., and such small torque values are easy to overtighten. Then you'll strip threads in the engine casing, and cry.

Here, "hand-tight" is fine, and actually preferable IMO.

For low-torque fasteners like these, I use a screwdriver with a socket adapter, rather than a ratchet. You can more easily feel the torque you're applying, and do not have a lever arm, so it's harder to overtighten.

Provided you use a new gasket, you shouldn't get oil leaks.

For tightening pattern - nothing is specified in the service manual, so whatever you want.

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post #6 of 6 Old 04-03-2019, 04:27 PM
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For the light stuff you can get an "INCH POUND" torque wrench.
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