|
SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Permanent Removal of Head Covers /cgi-bin/YaBB.pl?num=1418608550 Message started by KennyG on 12/14/14 at 17:55:50 |
|
Title: Permanent Removal of Head Covers Post by KennyG on 12/14/14 at 17:55:50 Can the chrome head covers be permanently removed for a "Retro Look" to the engine? Perhaps there is already a posting on the forum showing how to do it, but I cannot find it. Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by justin_o_guy2 on 12/14/14 at 18:41:47 Dude,, take them off. |
|
Title: Re: Permanent Removal of Head Covers Post by KennyG on 12/14/14 at 20:02:10 Justin, Cool. Are there any postings with instructions on how to take them off? And any modifications required? Fellow Texan, Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by justin_o_guy2 on 12/14/14 at 20:15:54 I don't remember just exactly what has to be done to get them off and When they are off,do any bolts have to be put back, maybe need shorter,,, I don't know... it's been a long time since I pulled mine off and I put them on every time... Sorry,dude. |
|
Title: Re: Permanent Removal of Head Covers Post by verslagen1 on 12/14/14 at 22:00:23 remove 2 bolts each side, toss covers over shoulder. there's a long bolt up front on the left side. you'll need to stack up washers or make a spacer for it. only way to remove bolt is to pull the head cover. |
|
Title: Re: Permanent Removal of Head Covers Post by justin_o_guy2 on 12/14/14 at 22:11:46 How about run a nut down and cut it off? |
|
Title: Re: Permanent Removal of Head Covers Post by KennyG on 12/14/14 at 22:13:56 Verslagen, Thank you very much. I am going to wait until I have a few more miles on the S40 before I do anything that the dealership can find to void the warranty. I cringe at the thought of taking the bike to the service department that prepared the bike for me when I bought it a few weeks ago. I am hoping to fix any minor problems myself with the information posted here on the forum. I will keep my fingers crossed that there is no serious warranty work If the guys in that service department worked for me they would be mending shoes. Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by justin_o_guy2 on 12/14/14 at 23:19:40 Don't take it back.. ever.. I have seen at least two engines destroyed,not damaged, junk,, because dealership MECHANICS put oil filters in bakkerds. |
|
Title: Re: Permanent Removal of Head Covers Post by KennyG on 12/14/14 at 23:33:31 Justin, The only thing good to be said about the dealer that I bought from is that they delivered the bike to my home. Both tires were 10 PSI low and the carb was so gunked up I could not keep it running. Most of the fasteners for the exhaust system were loose and the story goes on and on. I am thankful that I didn't attempt to ride it home, I would have probably been killed dead. Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by koehlerrk on 12/15/14 at 03:17:16 7759527F4E5D4F543C0 wrote:
Sounds like the couple bike shops around here. Wouldn't trust those folks to turn wrenches on a mailbox! |
|
Title: Re: Permanent Removal of Head Covers Post by Dave on 12/15/14 at 03:33:14 Here is a photo of the long bolt at the left front. The long bolt does not have threads that run all the way down - so you need to install a spacer so you can tighten the nut down. This bolt holds the left front corner of the head cover tight....so it has to be tightened. If (when) you take the head cover off to fix the head plug leak....you can install a shorter bolt in this location to eliminate the need for the spacer. I used a piece of aluminum tubing for a spacer. |
|
Title: Re: Permanent Removal of Head Covers Post by Demin on 12/15/14 at 06:15:06 I just put an aluminum spacer on my bolt too.I pull the covers off all of my builds. http://p1.bikepics.com/2011/08/16/bikepics-2257981-800.jpg |
|
Title: Re: Permanent Removal of Head Covers Post by KennyG on 12/15/14 at 06:38:29 Thanks A lot Guys Removing the head covers appears to be easy enough. As often said a picture is worth a thousand words. As soon as I am certain that I am not going to have any major warranty issues I will pull the head covers off and do the white spacer on the carburetor. I have raised the seat and temporarily installed some home made handlebar risers to make the S40 fit to me. I removed the brass plug from the carburetor the first day that I rode. It is a lot more civilized than my Blast. Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by Dave on 12/15/14 at 07:03:25 Just so we don't get ourselves confused....... The "Head Cover" is the aluminum part that is bolted to the top of the cylinder head, and it holds the rocker arms and cam in place. The engine won't run without the head cover. The "Head Cover Caps" are the chrome decorative on the top.....the engine runs just fine without them. http://www.hondaofflorence.com/fiche_section_detail.asp?section=432111&category=Motorcycles&make=SUZUKI&year=2005&fveh=10118 |
|
Title: Re: Permanent Removal of Head Covers Post by stinger on 12/15/14 at 07:22:20 Begins to unwrap the chrome head cover caps I was mailing to you all as Xmas gifts.... :-[ |
|
Title: Re: Permanent Removal of Head Covers Post by KennyG on 02/01/15 at 23:01:47 Dave, I think I understand the procedure for "Permanently Removing The Chrome Head Cover Caps". And your explanation of the spacer for the front bolt on the shifter side tells me what I have to do. With the other 3 bolts do I just screw them back into the head, or head cover? Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by Dave on 02/02/15 at 03:41:11 [quote author=51564B4C454750220 link=1418608550/0#14 date=1418656940]Begins to unwrap the chrome head cover caps I was mailing to you all as Xmas gifts.... :-[/quote] We are mailing all the unused covers to Serowbot. He is going to use them to make a chrome Armadillo mailbox. |
|
Title: Re: Permanent Removal of Head Covers Post by Dave on 02/02/15 at 03:42:33 18363D102132203B530 wrote:
Just put the other 3 bolts in the box with the head cover caps, and mail it to Serowbot. You don't need them as their only function is to hold the head cover caps in place. |
|
Title: Re: Permanent Removal of Head Covers Post by justin_o_guy2 on 02/02/15 at 05:49:41 And,as for the long, upside down bolt, I don't see why running a nut down and cutting it off wouldn't work better.. |
|
Title: Re: Permanent Removal of Head Covers Post by Dave on 02/02/15 at 05:51:50 415E585F42457444744C5E52192B0 wrote:
The long upside bolt doesn't have threads that run all the way down...you have to install a sleeve that covers up the un-threaded portion so the nut can be tightened down. http://www.hunt101.com/data/500/medium/Sand_and_crap_by_plug.JPG |
|
Title: Re: Permanent Removal of Head Covers Post by justin_o_guy2 on 02/02/15 at 06:12:11 WELL Dave,, that right there is reasonable... Me, I'd wanna get the head off of the bolt, pull it, drop a shorter bolt in and get a nut on it, If there is room with the chrome gizmo gone.. but the stack looks tacky to me. You bring me that bike for a year and I would fix that for you... I would. Really. |
|
Title: Re: Permanent Removal of Head Covers Post by Dave on 02/02/15 at 06:21:38 796660677A7D4C7C4C74666A21130 wrote:
(That photo I took from the Rubber Plug repair thread in the Tech Section....it is not my bike). When I rebuilt mine and had the cylinder head off....I put in a threaded rod that was cut to the long length with a nut on the bottom that was "thread lockered" on real good! That way I could remove the long stud and put in a shorter one later on when I removed the head covers.......the engine went back in with the stock head covers on as the Cafe' conversion was a year later. My gas tank sits so low that you really can't see the long stud unless you get down to look it it.....but I will fix it this winter so it doesn't bother you. I betcha you could fix this is less than a year.....if you stopped riding it for a few minutes! ;D |
|
Title: Re: Permanent Removal of Head Covers Post by justin_o_guy2 on 02/02/15 at 06:31:30 You're right, I'm busted,, I would fix it the day you come to get it. Please deliver it with fresh rubber on it... |
|
Title: Re: Permanent Removal of Head Covers Post by KennyG on 02/02/15 at 06:46:49 Dave, One final question and then I will leave you guys go back to arranging transportation for your bike to Justin 'O: Is their any special torque requirement for tightening the remaining long bolt after removing the "Chrome Head Cover Caps"? Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by Dave on 02/02/15 at 06:54:05 69474C615043514A220 wrote:
Just torque it to the same tension as the other 6mm head cover bolts....5.9 - 8.8 ft. lbs. This is really just "snug" with a small 6mm hex end wrench. Don't crank down on these bolts as they are small and easily stripped. |
|
Title: Re: Permanent Removal of Head Covers Post by justin_o_guy2 on 02/02/15 at 06:58:27 Feel of it,don't strip it, if it leaks, give it a little bit more. A healthy bolt and nut have a feel when they hit Max clamping force, PROVIDED you are holding the tools in a manner that Allows you to Feel it. |
|
Title: Re: Permanent Removal of Head Covers Post by KennyG on 02/02/15 at 07:10:20 Dave & Justin, Thank You! I never broke a bolt or stud or stripped the threads on a motorcycle until I bought my first torque wrench. LOL Unless it is inside the engine, or transmission, I don't use a torque wrench, I just make fasteners "Good N' Tight. Or as Justin says I tighten by "Feel". :o Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by Dave on 02/02/15 at 07:22:13 When I got my bike...it was 3 years old but well taken care of. When I changed the oil.....I had to use both hands on the wrench and wedge my foot against the frame to get the oil drain plug loose! It was waaaay too tight....and unfortunately that is not all that uncommon. A lot of folks tighten things more then they should. |
|
Title: Re: Permanent Removal of Head Covers Post by KennyG on 02/02/15 at 07:38:20 After I re-assemble anything on a motorcycle I go for a ride and come back to the house and go over all of the fasteners to check for "Tightness" and snug everything up again. I will check the fasteners again after the next ride and if I have to tighten anything again I will use Blue Loctite. If after the next ride I find anything that needs "Tightened" I will safety wire it. The "Big Singles" that I rode back in the "Olden Times" vibrated everything loose, including spot welds. If you wanted to ride a "Big Single" you would become acquainted with "Safety Wire". Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by 49mack on 02/02/15 at 11:31:32 When I removed my head cover caps, I replaced the vacated bolts (except the left front) and installed cleaner, better looking bolts in their places with lock washers. As for the left front, I have a hack saw blade holder and just sawed it off. A complete hack saw won't fit and a Dremel cutoff wheel is not long enough. I held the protruding top of the bolt with vise grips and sawed at the bottom of the bolt. When cut through, the bolt head slides out easily and the severed bolt just pulls straight out. Blow out the chips and go ride! |
|
Title: Re: Permanent Removal of Head Covers Post by Dave on 02/02/15 at 11:39:41 6A707D7C7A786B2E2D190 wrote:
That left front bolt also holds the front corner of the head cap in place, and it should be replaced with a shorter bolt so that corner of the cap is torqued down in place. You may be able to get by without it......but I believe it should be replaced so the head cover was designed to be bolted down in that spot. You can use a short piece of threaded rod, and a nut on each end......apply the red thread locker on the bottom one so the nut stays in place once installed....and you can use the skinny vice grips you used to take the bolt head out. |
|
Title: Re: Permanent Removal of Head Covers Post by KennyG on 02/02/15 at 12:18:08 Dave, I am going to use a spacer on the existing bolt, on the chrome head cover cap, and tighten it properly. I will wait until there is a reason to take off the head cover to replace the bolt with a shorter bolt.. Mack, I am too ham fisted to get a hacksaw blade in that little bit of space without scratching up the engine. Kenny G |
|
Title: Re: Permanent Removal of Head Covers Post by Gary_in_NJ on 02/02/15 at 13:05:42 While I haven't tried it yet, I've looked at this closely and I'm quite sure that the head of the bolt can be cut using a metal blade on a jig saw. It may be a two person job; one to control and tightly hold the saw and another to steady and push down on the bolt. Once loose the head can be removed via access by the decomp lever. |
|
Title: Re: Permanent Removal of Head Covers Post by Flint on 02/02/15 at 23:20:04 Removing the head covers might actually decrease the oil temp a bit by allowing airflow over the top half of the cylinder head. Personaly I like the looks of the bike as is. Can't wait till spring. -22 as I am typing this :-/ |
|
Title: Re: Permanent Removal of Head Covers Post by justin_o_guy2 on 02/03/15 at 03:20:16 Maybe run a die down the bolt? |
|
SuzukiSavage.com » Powered by YaBB 2.2! YaBB © 2000-2007. All Rights Reserved. |