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Message started by mick on 11/10/08 at 18:53:36

Title: cylinder head cover
Post by mick on 11/10/08 at 18:53:36

I'm having one heck of a job getting the head cover off.
In the clymer book ,it just says take out head cover bolts and lift the cover off,I have been struggling with it all day, the book says to leave the bolt in that has a concave head and marked with an "A", all the bolts have a concave head,there isn't one marked with a "A" ,the only odd ball one is in the spot they indicate , that has a phillips hex head,it says that one holds the exhaust valve rocker arm shaft in place and must be left in place at this time,but it doesn't say when to remove it.
Does any one know if the cover is usually stuck tight?
I have noticed so far that just about every nut and bolt has a lock tite
on it,I'm wondering if the last person to work on it used a similar gook on the gaskets.
Darn thing is starting to drive me nuts,any help would be appreciated.

http://i495.photobucket.com/albums/rr311/mickrowe37/003-1.jpg

Title: Re: cylinder head cover
Post by verslagen1 on 11/10/08 at 19:40:10

Yes it was hard to get off.
And there's bolts hidden all over the darn thing.
Did you get them all?

http://verslagen.savageriders.com/CamChainClub/HeadPattern01web.jpg

Title: Re: cylinder head cover
Post by Reelthing on 11/10/08 at 19:54:07

some can be missed - did you print the diagram out put it on a box and punch a hole for each? - they are different lengths as well - if you're sure - really sure all the bolts are out - and you have it at TDCC - I'd turn the engine over real slow an let the cam pushing against the rockers pop it loose

Title: Re: cylinder head cover
Post by beck on 11/10/08 at 19:55:05

I took mine off this weekend. You left the right bolt in place. Unless you want to take the rocker arm out of the head cover you do not need to remove this bolt. If your just changing the oil plug you will let it in. You did remember to take the 2 bolts out located under the rocker covers (L25) right? Mine was easily lifted with a wide blade screwdriver. It had not been off before so it was just the factory sealant.
Using the paper stuck to a box is a great help as stated above. You will get the bolts mixed up if it isn't used. Sooner or later you will turn the cover over and they will all fall out.
When you get it off I posted a question earlier that you can easily answer. There are thrust washers on each of the rocker arm shafts. I took my rocker arms out of the head and don't remember which side of the rockers they were on. You will see them when you turn the cover upside down. The thrust washers are just thin washers with waves. Your help would be appreciated.

Title: Re: cylinder head cover
Post by mick on 11/10/08 at 20:07:48

4C5E534B1259535E4B124B50523F0 wrote:

A HA that must be it ,those two little buggers L25s,are still in,when I get it off I will take note of the the wavey washers,before I make my next move though I'm going to find a box and make a drawing of the cover and where the bolts go,it will have to wait til the morning now,I am into my second night cap,I never drink and ride or drink and work on the bike eather. thanks for the help.

Title: Re: cylinder head cover
Post by Trippah on 11/10/08 at 20:13:18

I fdound that somehow I missed the bolt L-70 dead senter when trying to remove the head,(despite haveing a bolt in the L-70 location on my cardboard "organizer") It is located directly under the frame member that passes over the engine obviously :D, and is easy to miss if you are doing the job with the engine still in frame.

Title: Re: cylinder head cover
Post by Reelthing on 11/10/08 at 20:15:50

so what did you have in the L-70 hole in the cardboard?

Title: Re: cylinder head cover
Post by Trippah on 11/10/08 at 20:24:11

Well, 6 months later, I still haven't managed to get the money together to get the exhaust header bolt edm'd out, estimated cost $160. so, I haven't tried to put it back together, and I fear when I do, I'll find out too late what it is. :D
The now year long repair job is primarily due to family financial crisis, whenever I get a little mooney, I have too many places to spend it. If I find a job, hopefuly I'll get the beast back together. ;)

Title: Re: cylinder head cover
Post by serowbot on 11/10/08 at 20:29:12

Wondered where you were Mick,

Anyway, the bolt numbers in the pic Versy posted are bolt lengths if you loose track,...I did...
One of them,...I think it's L70, needs to go in before you put the cover in place, or the frame will get in the way.
And don't forget the vent tube screen, I did....
If she won't give,... a gentle twist with a wide flat blade screwdriver between the fins will make her release...near that timing chain cover plug...
I done it four times now, on three different bikes, and it feels like the first time every time...early senility...

Good time to dump the chrome head covers if your so inclined,... 'cause you can leave that bolt out by the spark plug that becomes useless without the cover.

PS,...mailed your DVD's back to you on thursday, let me know when they're safely back in your hands,...Thanks
Serowbot

Title: Re: cylinder head cover
Post by mick on 11/10/08 at 21:01:19

Thanks Gentlemen for all your help,I have a feeling it will be ok in the morning.
Serowbot,I did get the CDs back ,and thanks for" girl on a motor cycle"
and "on any Sunday" I watched girl; last night sexy little thing,
weird helmet though.

Title: Re: cylinder head cover
Post by serowbot on 11/10/08 at 21:53:26

Yeah,..weird flick all 'round...
If you haven't seen "On Any Sunday"... it's much better.

Trivia- the little boy riding a wheelie on the minibike in the pits at the start,...would later become champion motocrosser/motard racer Jeff Ward. First motocross rider in history to win every major AMA motocross national championship.

Title: Re: cylinder head cover
Post by beck on 11/11/08 at 06:02:24

[quote author=24202A223D212C2520242C30490 link=1226372017/0#4 date=1226376468
I'm going to find a box and make a drawing of the cover and where the bolts go.[/quote]

It's a lot easier to just take the head cover photo above and put it on the copy machine. Enlarge it as big as your paper will allow. (The machine I use has the big stuff) It doesn't matter if it is not the exact size as the cover. It is just a reference and a place to store the bolts.

Title: Re: cylinder head cover
Post by mick on 11/11/08 at 06:10:37

6A78756D347F75786D346D7674190 wrote:

[quote author=24202A223D212C2520242C30490 link=1226372017/0#4 date=1226376468
I'm going to find a box and make a drawing of the cover and where the bolts go.

It's a lot easier to just take the head cover photo above and put it on the copy machine. Enlarge it as big as your paper will allow. (The machine I use has the big stuff) It doesn't matter if it is not the exact size as the cover. It is just a reference and a place to store the bolts.

[/quote]
yep that was my intention,I made up two copies,one for future reference and one to stick on a piece of cardboard or box,just as I laid
my head on the pillow,it dawned on me.

Title: Re: cylinder head cover
Post by verslagen1 on 11/11/08 at 07:42:20

I actually stuck the bolts on the line near the nomenclature so that I could clearly see where it was supposed to go back.

Title: Re: cylinder head cover
Post by mick on 11/11/08 at 09:29:06

21333E267F343E33267F263D3F520 wrote:

Here you go Beck, good luck.

http://i495.photobucket.com/albums/rr311/mickrowe37/004.jpg

http://i495.photobucket.com/albums/rr311/mickrowe37/003-2.jpg

Title: Thanks Mick
Post by beck on 11/11/08 at 11:06:27

Thanks Mick. I owe you a cold one!

Title: Re: Thanks Mick
Post by mick on 11/11/08 at 12:29:06

20323F277E353F32277E273C3E530 wrote:

Thanks Mick. I owe you a cold one!

Any time, but it's me who owes you a cold one.
Take care ,ang good luck with reassembly.

Title: Re: cylinder head cover
Post by mick on 11/11/08 at 15:41:20

My next question, I did get the head off and every thing looks good,
for 16000 miles, it was very good,I guess I could have left it another
year before doing a valve job,but it's off now might as well do it.
I noticed that the head cover does not have a gasket,there was black stuff around the edge of the join,any one know what it is?
I just wonder why they don't have a gasket there,seems it has alot of oil sloshing about in there, any way, any recomendations's guys?

Title: Re: cylinder head cover
Post by Reelthing on 11/11/08 at 16:49:39

Just curious if you read all the post in this one?

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1099227295

Title: Re: cylinder head cover
Post by mick on 11/11/08 at 18:34:49

7F484841594544434A2D0 wrote:

Just curious if you read all the post in this one?

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1099227295

Thanks reelthing ,good info ,I'm glad I read it ,the plug cap looked ok but i think I will order a new one just in case.

Title: Re: cylinder head cover
Post by serowbot on 11/11/08 at 18:40:28

No gasket there...I use Hondabond or Yamabond...witchever I got around. Put a little around that rubber plug when you replace it too.

Title: Re: cylinder head cover
Post by Reelthing on 11/11/08 at 20:12:49

63676D657A666B6267636B770E0 wrote:

[quote author=7F484841594544434A2D0 link=1226372017/15#18 date=1226450979]Just curious if you read all the post in this one?

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1099227295

Thanks reelthing ,good info ,I'm glad I read it ,the plug cap looked ok but i think I will order a new one just in case.
[/quote]

Those dern plugs are just about a one use without sealant - like the factory does - the head gets hot and the rubber sticks to the passageway - I do believe the dealers cause these bikes to leak - they don't stock the rubber plugs and if they really do a re-torque of the head bolts at 600-1000 miles they just pop the old one back in there without sealant because the Suzuki shop manual doesn't call for it and a future leak is ready to happen

Title: Re: cylinder head cover
Post by Digger on 12/05/08 at 21:10:59

3B2D3A273F2A273C480 wrote:

.....Anyway, the bolt numbers in the pic Versy posted are bolt lengths if you loose track....

Serow,

Brilliant! I've had the head cover off of mine twice so far and never figured this out. The first time I had it off, I painstakingly measured the length of each bolt myself (in inches) and recorded the info in case I got 'em mixed up. It never occurred to me that the diagram already gave you the length in mm.

I'm a dope!