Delivered the engine covers to the polisher this morning. Greg had no work lined up, so I really hustled to get them over to him. A few of you asked me to detail the generator cover removal and I have to apologize for the lack of photos. Before you start, drain any oil from the crankcase or it will pour out when you pull the trans cover. If you are working on the side stand, most of that oil will be on the opposite side, so don’t bother. Keep an oil pan under both covers.Here’s what I did:
1. Knock all the Philips head screws loose a turn with a hand held impact tool. Don’t forget the three around the “HONDA” script on the alternator. They hold the fixed centre (#1 in the photo).
2. Remove the two screws and pull off the sprocket cover.
3. Pull out all the screws out of the transmission cover and remove it. You can start tapping it loose at the back (the part visible when you removed the sprocket cover). You will notice a wire harness that comes from the alternator. It also includes the single wires from the neutral switch, oil pressure switch and the bigger one that feeds the starter motor from the solenoid. They can be left there for now. The trans cover comes off without them. Inspect the transmission cover. It has two hollow dowel pins in two of the screw holes. If they are loose, remove them. If they are stuck in the case or the cover, just leave them there. If the gasket tears apart you will have to clean off both faces and replace it. Get a new one ahead of time.
4. Remove the starter motor cover so you can see the two wires that go in there. I usually unscrew the wire eyelets from the neutral switch (bottom of the crankcase) and oil pressure switch so they can come away freely when you pull the alternator.
5. Remove all the alternator cover screws and and pull the cover off. There is one spot to pry at in the lower front. Take note of the starter motor spur gears in the top right corner (#4 in the parts photo). If it falls out, don’t worry. All the wires will come with it and it will also drip a small amount of oil. Sit the “pot” on the bench so you can look inside. Note: it has a single hollow dowel. Treat the same as those in the trans cover. Don’t lose it. The alternator also has a gasket. Save it if you can. Replace if torn or damaged.
6. #3 in the parts photo is a clip that secures the wires in the housing. Take a picture of how everything sits and take out the clip. Below the clip, all the wires are held in a rubber block. Gently pull it out with the encased wires. Part #2 is held in by four Philips head screws around the perimeter. They are oddly threaded 1/2 into the case AND 1/2 into the part #2. The only way to get these loose is with the hand held impact driver. Get a partner to hold the case steady on a good bench and hit it square. They MUST come out cleanly. There is no drilling them out! You’ll see why when they are out. Once they are removed the ring will lift straight up and away.
7. The centre ring (part #1 in the photo) is held in by the three screws around the “HONDA” script. Remove them from the outside, and take it out. Mark (Hondaman) suggests there are small copper washers under these screw heads. I never noticed, and in my rush forgot to check today…..
Questions?
