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Message started by jimmysmooth on 03/16/14 at 08:29:12

Title: Broken clutch cover bolts
Post by jimmysmooth on 03/16/14 at 08:29:12

Recently I took my clutch case cover off to check my tensioner. When I put it back on, I over torqued a couple of the bolts and even broke one. I should have bought a torque wrench. Now I have the wrench, but I can't find replacement bolts anywhere. The hardware stores around me (St. Louis) don't sell a lot of chromed bolts, and Bike Bandit has them on their diagram but doesn't have them listed with a price. I am talking about number 5 and 6 on their diagram. Does anyone have any idea where I can buy or order these?

Title: Re: Broken clutch cover bolts
Post by S-P on 03/16/14 at 08:37:39

BUY A TORQUE WRENCH, NOOBS!!! :'(
Ebay sellers often have sets for about 15.00. I'd check there. Probably less than an individual OEM bolt.

Title: Re: Broken clutch cover bolts
Post by verslagen1 on 03/16/14 at 08:48:15

ace hardware is supposed to have a large collection.

or

http://www.partsoutlaw.com/oempartfinder.htm?aribrand=SUZ&arian=Motorcycle#/Suzuki_Motor_of_America%2c_Inc/LS650P_%282003%29/CRANKCASE_COVER/02040008/5602040004

$1.16 a bolt

Title: Re: Broken clutch cover bolts
Post by Kris01 on 03/16/14 at 09:21:05

Boltdepot.com

They have a pretty large selection of anything that I've ever needed.

By the way, what size are those bolts?

Title: Re: Broken clutch cover bolts
Post by justin_o_guy2 on 03/16/14 at 09:34:44

Torque wrench? Naah, 1/4" ratchet & No Closed Fist on it. Thumb on ratchet head & squeeze fingers in, FEELING the bolt as it snugs up. YOu can feel it when it stops. If it leaks, snug a bit more where you think you must, but bolts will tell you when its time to stop, once you learn how to listen,

Title: Re: Broken clutch cover bolts
Post by jimmysmooth on 03/16/14 at 12:13:03

Thanks, I will check those websites out. I was pretty concerned about tightening too much, so I hand tightened them with a hex bit on a screwdriver. Then it oozed out at the seal. So I tried a little tighter with ratchet, but I went too far.

Title: Re: Broken clutch cover bolts
Post by justin_o_guy2 on 03/16/14 at 14:24:56

Id rather have to snug several times than replace busted stuff..
Things dont always go so smooth, ehh Jim?

Title: Re: Broken clutch cover bolts
Post by S-P on 03/16/14 at 17:43:45

27383E3924231222122A38347F4D0 wrote:

FEELING the bolt as it snugs up. YOu can feel it when it stops....bolts will tell you when its time to stop, once you learn how to listen,

JOG, the Force was weak in this one.... :D

Title: Re: Broken clutch cover bolts
Post by old_rider on 03/16/14 at 18:34:45

65666262767C6260607B670F0 wrote:

Harbor Freight has cheap torque wrenches sometimes if you have a coupon or they are having sales
http://www.harborfreight.com/catalogsearch/result?q=Torque+wrench

I'll look around to see if I can find a place with a parts listing of the bolts

here is a bike parts site with breakdown, see if you can find the bolts and if it tells you the size

http://www.bikebandit.com/1997-suzuki-savage-650-ls650p/o/m147792#sch239634

Title: Re: Broken clutch cover bolts
Post by WD on 03/16/14 at 20:38:30

Home Depot, Lowe's, Ace, etc. Any place that sells stainless steel metric allen bolts. You really don't want chromed mild steel fasteners rotting away on a visible section of the engine.

And forget about o.e.m. style paper gaskets, gray goop (high temp rtv) works better.

The only easily serviced, torque wrench required fasteners are the clutch basket and drive pulley ones. Everything else, finger tight, retension after a heat cycle or two. You may want a torque wrench for the head cover nuts, but, until you are forced to replace the cam chain, you don't really need one. Even the tensioner widget is just held on with a circlip...

I'm odd, my bike has leaked like an old Triumph Bonneville or pre-Magnum Dodge truck engine since day one. Haven't checked the valves in years, every time I checked them the gap was within spec.

You guys worry too much.

Title: Re: Broken clutch cover bolts
Post by justin_o_guy2 on 03/17/14 at 10:05:48

I watched the soft point on the valve adjuster mush down & work harden,
I watched the valves slowly stop needing fiddled with. At 20,000 I tightened them up, just because I want them set on the tite side.

Title: Re: Broken clutch cover bolts
Post by Michael L on 03/17/14 at 10:18:05

Are you sure you didn't strip the threads in the alu casing...? I find it hard to believe you broke a steel bolt before stripping the thread.. Anyway, just as justinoguy explained, that's the only right way to go.. A 1/4 with a snug hand and you're done.. IF it would begin to leak, in which I doubt it will, you can just give them 10 degrees more...

Title: Re: Broken clutch cover bolts
Post by justin_o_guy2 on 03/17/14 at 11:36:25

Get 2 plates, put a bolt thru, put a nut & bolt in, use 1/4" ,, something small, use cheap, crappy bolts & feel of them. Strip a few, get close to stripping them, pull a nut & flip it & try to put it back on.. Youll know it was stressed if it wont go "upside down". The threads will be distorted.
Youll get the feel of a bolt that has hit its max clamping force. Yea, youll waste an hour or more & spend a coupla bucks on stuff to ruin, but in the long run, youll save hours of hassles & who knows how many dollars.

Title: Re: Broken clutch cover bolts
Post by S-P on 03/17/14 at 12:56:49

4D5254534E4978487840525E15270 wrote:

What is the benefit to a bit on the tight side (except maybe eliminating the tick). On my VW they recommended a little loose so they didn't burn.

Title: Re: Broken clutch cover bolts
Post by justin_o_guy2 on 03/17/14 at 15:47:27

On the tight side of the specs,, not tighter than spec, ever. Hey, I paid for a cam that lifts & holds them open,, the least I can do is set them to open as far as I can, safely..

Title: Re: Broken clutch cover bolts
Post by jimmysmooth on 03/17/14 at 18:51:40

142B6E6D6868580 wrote:

Yeah Justin, one bolt snapped and the others twisted thin between the outside of the case and the holes. The one that broke came right out with a pliers.

Title: Re: Broken clutch cover bolts
Post by justin_o_guy2 on 03/18/14 at 06:45:46

IF you get stronger bolts, then youll be all set up for wrecking threads in the case. Stay with wimpy bolts. Theyre strong enough to do the job of clamping the case on tight enough to not leak.

Title: Re: Broken clutch cover bolts
Post by seedubs1 on 03/18/14 at 07:10:08

A $20 torque wrench is a lot cheaper than breaking stuff and saves a lot of time fixing overtorqued/broken parts.

I'm notorious for overtorquing everything if I do it by hand. I always use a torque wrench. Saves a lot of hastle.

Title: Re: Broken clutch cover bolts
Post by verslagen1 on 03/18/14 at 09:05:56

They were on sale not too long ago for $10 any size

Title: Re: Broken clutch cover bolts
Post by shorty on 03/18/14 at 09:34:48

687771766B6C5D6D5D65777B30020 wrote:

yes sir, 1/4 drive with just 2 fingers, after 40yrs wrenching can definitely tell.... Now head bolts DO get a torque wrench ;D

Title: Re: Broken clutch cover bolts
Post by S-P on 03/18/14 at 10:37:04

41535C415D5C5755320 wrote:

yes sir, 1/4 drive with just 2 fingers, after 40yrs wrenching can definitely tell....

As I used to tell my sheetrockers "There's a difference between 40 years of experience and one year of experience 40 times". ;)

Title: Re: Broken clutch cover bolts
Post by justin_o_guy2 on 03/18/14 at 12:44:00

Of course I have & use torque wrenches.. There are places where theyre just a Must, but just because a bolt has a torque spec that doesnt mean a torque wrench must be used. Another thing about these bikes, you look at those torque specs,, on a lot of them the specs are wide , like
Torque 25 to 40 pounds, not quite like putting a valve body in a transmission, where theyre using inch pounds & working a triple pass patern.