Generator cover replacement

panagos1 · 05-17-2006, 2:30 AM

I need to replace the generator cover of my 03 600rr. I have a new cover and unbolted the old cover but couldn't get the cover off. Do I take a screwdriver to it or is it bolted from the inside? I noticed 4 threaded inserts inside the cover, i assume it is how the generator bolts is but we know what assuming does...

Thanks for any help on the issue, love the bike.

G-Force Junkie · 05-17-2006, 3:26 AM

Usualy you have to unbolt the stator assembly from the cover. Either do this with it still wired to the bike, or follow the wires and unplug them and pull the cover with the stator off and swap it into the new cover. Usualy there are a few bolts holding it on, and sometimes a metal tab or similar to hold the wiring harness. Where the wires pass through, there is usualy a molded grommet that slides in a notch on the cover.

HondaGalToo · 05-17-2006, 5:17 AM

Like G-Force said, once you get the cover off, the stator assembly needs to be unbolted from the cover.
Sounds like you're having trouble getting the cover itself off? It's got a very strong magnetic pull. It's probably like my 929, I thought for sure I hadn't unscrewed a bolt or something, or that I was going to pull the bike over on top of me. It'll come off, just gotta pull at it.
I haven't seen a 600 cover, but I assume a wire comes out of the top? If so, get some RVT blue to reseal it up when you replace the cover. Use a new gasket, too.

BDA116 · 05-17-2006, 9:28 AM

Take a rubber mallet or block of wood and a hammer and tap the cover a few times on the side in a couple spots.
Then pull good and hard. If you have all eight perimeter bolts out, there is nothing else other than the magnetic pull and the cured liquid gasket holding it on.

Do NOT use a screwdriver. All you will accomplish that way is dinging up the mating surfaces and cause yourself more work.