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2006 model - Alternator cover needs replacing...

3K views 13 replies 7 participants last post by  Leo@hinton 
#1 ·
Hi all,
New to this forum and the bike so looking for help info. After 700 miles (1 week of ownership) I dropped my pride and joy off its stand!! This has upset me deeply and one of the things that needs replacing is the Alternator cover (Cost over 100GBP!) I have the Kawasaki workshop manual and all seems ok to remove the cover. Then the instructions go manic when you have to remove the stator from the cover?? It goes on about having to lift the tank and undo engine mounting bolts?? Surely not?? I would say I am ok with the spanners and would rather do this myself, but can I remove the stator from the cover and put it in the new one without dismantling the whole bike!!

If anyone has done this job can you give me any advice/tips? Don't really want to have the dealer do it as they are a long way from where I live.

Thanks

p.s. Great bike by the way, I love it but see my other post about 5th gear clutch noise!!
 
#3 ·
I think the manual only goes down that route so you can remove the cover from the bike completely with the internals and wiring still attached.

I've got a 2001 A2 so as long as it's the same just unbolt the cover bolts and pull the cover off. It'll be held on magentically fairly strongly. Then you should have 2 bolts retaing the wiring and 3 bolts in the centre. Just unbolt old and bolt on new. The gaskets metal so it's reusable.

Just watch your fingers when you put it back on, the magnetic force will pull it out of your hands.
 
#10 ·
lie2me said:
spray paint both covers flat black with hi-temp paint and forget about it.
Still best to open it up and look inside even if it does only look scratched on the outside as the inside can actually be cracked. Mine didn't look to bad untill I examined it on the inside, spiderweb of cracks.

(Paint it silver, it'll be much faster)
 
#11 ·


good advice to check it for cracks.
I just cleaned mine up, filled the scrapes in with a primer, scuffed up the cases with scotch pad, and taped up everything I didn't want black paint on. The shot 3 coats of hi temp, flat black paint. It turned out very nice.

I was actually contemplating painting them before I jacked them up. I'm just not a huge fan of that color on the cases.
 
#13 ·
yeah the tank bra is LP.

As far as the Independent... I dig the design from my sons skateboarding stuff. And I don't like riding with anyone that I don't know...MCs suck. Kinda my own way of saying 'leave me the fuck alone' or 'your MC can kiss my ass'. There are a LOT of silly-ass biker boy clubs around here and I don't want anyone to associate me with them.

the bike is completely naked now though and completely stock.

 
#14 ·
shiggsy said:
I think the manual only goes down that route so you can remove the cover from the bike completely with the internals and wiring still attached.

I've got a 2001 A2 so as long as it's the same just unbolt the cover bolts and pull the cover off. It'll be held on magentically fairly strongly. Then you should have 2 bolts retaing the wiring and 3 bolts in the centre. Just unbolt old and bolt on new. The gaskets metal so it's reusable.

Just watch your fingers when you put it back on, the magnetic force will pull it out of your hands.
+1, been down that road as well. And doubly so on the trapping of the fingers! :oops:
 
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