For this operation it is necessary to either drain the engine oil or lay the bike over onto its left handside.  Before you can remove the engine cover you will need to remove/disconnect the following:
  • Bashplate (if you have one)
  • Engine oil filter cover and filter
  • Rear Brake pedal
  • Oil line banjo
  • Clutch cable/arm

  • Remove cover bolts and place in such away that you know which ones came from where as they are of different lengths. 
  • Pay particular attention to the bolt circled as it has a special sealing washer in that location
  • With a bit of luck, the clutch cover gasket will come away intact and not tear, otherwise a new gasket will be required
  • Note the locating dowels still in place on the clutch cover - do not lose these !

  • In the case you damage the gasket coming off or if you wish to have a replacement on hand just in case, the Suzuki Part number is:    11482-32E00

Removing the clutch pack is optional but I prefer to in order to more easily access the NSU and do a proper job
  • A clutch holder tool may be necessary to remove clutch pack
  • Place parts aside and stack the plates in the same order and direction as they came off to ensure correctness on reassembly.
  • Before touching the screws to remove them, test their tightness by finger (just for interest sake)
  • Unscrew the screws noting how loose or tight they were
  • Leave the NSU housing in place - there is no need to remove this.
  • Clean down the screws of oil 
  • Apply some blue loctite to threads
    • NOTE: be careful to use blue and not red loctite. The use of red will render the screws unremoveable in the future without the application of heat, which may in turn destroy the NSU switch and housing.
    • Some owners have also tie wired the screws but I think that is overkill
  • Reassemble and ride.