slickwill

I'm replacing a scratched alternator cover today on a 2002 F4i and have a couple questions.

First, the first thing in the instructions it to remove the throttle body? I think, just so that I can get access to the disconnect for the alternator? Where is this picture showing?

Is that under the throttle body somewhere? It seems ridiculous to go through the entire process of removing the throttle body just so that I can replace a stator cover.

Next question? It gives torque values for EVERY other bolt on the bike except the 9 cover bolts. Any idea on what I should go with?



Here where it says to put sealant on the cover in the area shown is it meaning only the dark area or everywhere but the dark area? Or should I just omit the gasket and put sealant all the way around?

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If it has wheels, I've crashed it, and some things that don't skis, snowmobile, card board box, giant tube, sentra, dirtbike, lawn tractor, grandmas bread tray, kayak, canoe, raft, bicycle, waterskis, tobaggan, horse, ATV, Now my CBR (women)

evl_twn

I'm not sure about the throttle body removal, but hopefully you can get by without.

Most case cover bolts are going to be the same, 9 ft lb. They should all be the same size as the other bolts listed, 6mm x 1.0mm. Check in the specs pages for general fastener torque, looking for 6mm. Be CAREFUL approaching torque on those, too. Use an inch-pound torque wrench if you have one, and go SLOW. A steel bolt threading into aluminum can easily strip the threads. Always better to use a little less torque than too much. If you're nervous about it, torque lightly but use blue Loctite.

The sealant only goes in the shaded areas, which is where your crankcase halves come together. Put a light coat of sealant (Threebond 1207B is the best case sealant I've used, sourced from Suzuki) just over those case joints, then set the gasket and cover over it, and bolt it on.

slickwill

Thanks, I'm going out right now to take a look at the throttle body situation.

__________________
If it has wheels, I've crashed it, and some things that don't skis, snowmobile, card board box, giant tube, sentra, dirtbike, lawn tractor, grandmas bread tray, kayak, canoe, raft, bicycle, waterskis, tobaggan, horse, ATV, Now my CBR (women)

evl_twn

Oh, on another note, if you're just replacing the cover and not the stator windings, you shouldn't need to touch the wiring connector at all. Just unbolt the stator from the case cover, then replace it with the new one, leaving the stator connected the whole time.

slickwill

That's what I figured would work because I am only replacing the cover. I just "thought" that maybe they had that in the directions for a good reason.

__________________
If it has wheels, I've crashed it, and some things that don't skis, snowmobile, card board box, giant tube, sentra, dirtbike, lawn tractor, grandmas bread tray, kayak, canoe, raft, bicycle, waterskis, tobaggan, horse, ATV, Now my CBR (women)

slickwill

One more question, do I install the gasket dry? It looks like it should use some sort of a gasket sealer, ala gaskacinch or something like that. The one that I took off doesn't really look like it had anything on it but yet it is distinctly hardened like something was used. The manual doesn't mention anything and on the other side for the clutch it specifically says to use sealant all the way around so maybe not for the alternator cover?

__________________
If it has wheels, I've crashed it, and some things that don't skis, snowmobile, card board box, giant tube, sentra, dirtbike, lawn tractor, grandmas bread tray, kayak, canoe, raft, bicycle, waterskis, tobaggan, horse, ATV, Now my CBR (women)

evl_twn

Gasket goes on dry, with the exception of the sealant used near the crankcase split.

slickwill

Thanks for all the help. Everything went pretty well and is back together. There was a point when I was wishing for a third hand though when I had all the sealant on everything and was trying to get everything back into place.

To bad I'm .5 qt short of being able to fully refill the oil. I thought I had a full gallon of Rotella. Apparently I'd already used a quart.

__________________
If it has wheels, I've crashed it, and some things that don't skis, snowmobile, card board box, giant tube, sentra, dirtbike, lawn tractor, grandmas bread tray, kayak, canoe, raft, bicycle, waterskis, tobaggan, horse, ATV, Now my CBR (women)