Poly Belt cover

[AndyCam]

OK I give up, I've removed the 4 allen bolts that hold the plastic cover on, the cover is loose and moves but will not come down off the casing!!
It seems not to want to come down past the suspension arm HELP

 

[Dec]

Once all bolts are removed it should just slide down.It is a thigh fit but it will flex abit.It needs to come toward the back of the wishbone first and then down to clear the pulleys if my memory serves me right,Don't be afraid to bend it abit.
Hope this helps.

 

[AndyCam]

Cheers Dec,
will attack with brute force right now

 

[DrFarkoff]

If it's cold where you are perhaps a spray with some hot water to prevent the plastic snapping with the cold???

Or gently warming with the heat gun before you go tearing and ripping stuff apart

 

[davegs]

Front cover

put it back and stick the whole lot on E-bay!.

 

[Steptoe]

OK I give up, I've removed the 4 allen bolts that hold the plastic cover on, the cover is loose and moves but will not come down off the casing!!
It seems not to want to come down past the suspension arm HELP

Have you a later bike ( post 2003/4 ?), If so ignore the previous posts as they don't understand what your going through

They have a different pulley on the alternator, it extends further out so making the cover very very difficult to drop down and get off . Your going to have to be a bit more brutal.

 

[fatbaldbob]

I too have recently had this problem (04GSA) I though it was just me! You will have equal grief when you try to get it back on.

I had mine off to do a belt change at 48K service, belt fitted was a 592, replacement belt bought from motorworks was 595? Having dropped the alternator (about 1mm was all clearance there was) belt was still too tight to come off so I cut it No matter how hard I tried the 595 would not go on, rang motorworks to check size as I have seen the size quoted on this site as 610, they told me that was the earlier model bikes and 04 0n is 595. Eventually got it on by removing plugs and having someone to turn the back wheel whilst levering it on to the pulley as the engine turned over. But still felt too tight for comfort, in fact it was so tight the belt needed no further tensioning. Feck knows how BMW fitted the 592 on it

Can anyone confirm the size for this year and model?

 

[sethmopp]

Have you got H&B engine bars fitted? If so, these will need to come off first, the only downside to these bars.

 

[fatbaldbob]

Have you got H&B engine bars fitted? If so, these will need to come off first, the only downside to these bars.

I have H&B bars on mine and did remove them, but the cover is still a bugger to get off, as steptoe says if you don't own a late model it's hard to understand why it's so difficult.

 

[Uncle Rob]

I too have recently had this problem (04GSA)

Can anyone confirm the size for this year and model?

its the larger 611 belt, and it can be just as easy to remove the bottom shock bolt and let the wheel drop,gives you that extra bit of clearance and no need to force the cover off

 

[Carl]

its the larger 611 belt, and it can be just as easy to remove the bottom shock bolt and let the wheel drop,gives you that extra bit of clearance and no need to force the cover off

Thats what I do too... hardly takes any extra time.

 

[Number 6]

I had similar issues with belt size, see here :-http://www.ukgser.com/forums/showthread.php?t=156998
Mine is a 2005 and the cover will pull down past the wishbone