Installation Instructions for Motorcycle Engine Covers and Cylinder Base Gaskets for S DR650SE Models (1996-2021)

Tools Required:

1. Socket Set: To remove and install the bolts on the engine covers and cylinder base.
2. Torque Wrench: To ensure bolts are tightened to the manufacturer's specifications.
3. Screwdriver Set: For any additional screws that may need to be removed during the process.
4. Pliers: Helpful for any clips or connectors that need to be removed.
5. Gasket Scraper or Razor Blade: To remove old gaskets carefully without damaging the mating surfaces.
6. Clean Rags: To wipe down surfaces and keep the area clean during installation.
7. Engine Oil: Use to lubricate the new gasket if specified by the manufacturer.

Installation Steps:

1. Prepare the Workspace: Ensure you have a clean, dry workspace with adequate lighting. Lay out all tools for easy access.

2. Remove Old Covers/Gaskets:

   • Begin by removing any necessary parts to access the engine covers and cylinder base.
   • Using your socket set, carefully remove the bolts and gently take off the covers.
   • Remove any remnants of the old gaskets using a gasket scraper or a razor blade. Clean the surface thoroughly with a rag.

3. Install New Gasket:

   • Position the new gasket carefully onto the clean surface. Ensure it fits snugly without overlap.

4. Reinstall Engine Covers:

   • Align the engine cover with the gasket in place. Begin inserting bolts by hand to avoid cross-threading.
   • Once all bolts are in place, use a torque wrench to tighten them to the specified torque settings in the owner's manual.

5. Reassemble Other Parts: If any other components were removed, reinstall them as needed.

6. Test for Leaks:

   • Start the engine and let it run for a few minutes. Check around the newly installed gaskets for any signs of oil leakage.

7. Final Check: Make sure all tools are removed from the area, and conduct a final inspection to ensure everything is secure.

Note: Always refer to the manufacturer’s guidelines for specific instructions and torque settings before beginning any installation.