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General Category >> The Cafe >> Clutch case gasket, or whatever it is called
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Message started by springman on 12/09/15 at 23:07:43

Title: Clutch case gasket, or whatever it is called
Post by springman on 12/09/15 at 23:07:43

Just finished changing the clutch cover gasket that was leaking. Took about 3 hours unfortunately. Taking the bike apart and putting it back together took about an hour and a half. Had trouble with one of the studs that holds the foot peg and brake pedal. It just slipped back into the cavity in which it is located. Pulled it back out with a magnet but kept sliding back in as I tried to put on the foot peg. I guess maybe a tack weld will hold it in place. Anyway the other hour and a half was spent scraping the gasket off the case cover. What a royal pain in the back side. I put a coat of grease on each side of the gasket this time hoping that next time I have to get in there I can reuse the gasket. Oh well, it is late. I'm all would up and felt like griping. >:(

Title: Re: Clutch case gasket, or whatever it is called
Post by Dave on 12/10/15 at 02:52:09

Guess what.....those bolts that hold the footpeg in place go all the way through the engine, and hold the footpeg on the other side....they are "through bolts"!

You could have just put another socket on the other side and held it in place while you put the washers and nut on. ::)

Title: Re: Clutch case gasket, or whatever it is called
Post by youzguyz on 12/10/15 at 03:08:43

Which goes to show that working on something when it is late, and you are tired, is going to result in "this doesn't seem right" moments.

I'm just surprised you could pull it back with a magnet. Usually has a lot more resistance from going through the spacer, engine, left peg assembly. And.. you got the nut to tighten down OK without a wrench/socket on the bolt on the left side?

Title: Re: Clutch case gasket, or whatever it is called
Post by springman on 12/10/15 at 09:01:29

Thanks for the comments gentlemen. First, no I was not able to tighten it down correctly. Second, I really do not think this one particular stud goes all the way through, I am guessing it was modified at some point. However I will check it as soon as I can. Dang, now I cannot stop thinking about it trying to visualize it. Thanks, I'll let you know what find.

Title: Re: Clutch case gasket, or whatever it is called
Post by youzguyz on 12/10/15 at 13:37:08

It goes through.. trust me. Both of them do.

I don't see a safe way to modify it, so I hope no one has done so. Those bolts are engine mounts, and hold the crankcase halves together.

Number 21 here:
http://www.ronayers.com/oemparts/a/suz/50d32fb3f8700232d0b3d917/crankcase

Title: Re: Clutch case gasket, or whatever it is called
Post by springman on 12/11/15 at 10:23:59

Thanks for the diagram youzguyz. It was my wedding anniversary yesterday so I have not yet gone back to take a look at the bike. Will get to it this weekend.

Title: Re: Clutch case gasket, or whatever it is called
Post by Art Webb on 12/11/15 at 19:04:37

Happy Anniversary David! And to your lovely missus!

Title: Re: Clutch case gasket, or whatever it is called
Post by springman on 12/11/15 at 19:56:18

Thanks Art.

Title: Re: Clutch case gasket, or whatever it is called
Post by springman on 12/11/15 at 20:32:51

By Jove, that is a through bolt!!! Vell, it is guut und tite now. Danke mein friends.

Unfortunately it seems to be leaking even more now. Well, I re torqued the bolts on the case, and yes they seemed a lot looser than what I had left them. We'll see if that took care of the leak if I get a chance to ride tomorrow.

Anybody know the torque specs on the clutch cover bolts. I actually do have a torque wrench which I should probably use. ;D

Title: Re: Clutch case gasket, or whatever it is called
Post by verslagen1 on 12/11/15 at 20:52:23

digger says...

Quote:

For my bike (see signature), the FSM lists the torque range for these bolts as being 3 -5 ft-lbs. If the bolts are hardened, then the torque range is listed as 6 - 8.5 ft-lbs.

I don't think that these particular bolts are hardened.

Title: Re: Clutch case gasket, or whatever it is called
Post by springman on 12/12/15 at 08:02:29

Thanks Versy.

Title: Re: Clutch case gasket, or whatever it is called
Post by justin_o_guy2 on 12/12/15 at 16:46:05

The wrench is what I used. I can FEEL the bolts clamping force and when it is as tight as it can tolerate.
Spend time, go slow, snug each, go again, back and forth, feel it snugging down, once it's pretty tight, just go around, and around, and around,,

Title: Re: Clutch case gasket, or whatever it is called
Post by springman on 12/12/15 at 17:50:29

Well I got out the 1/4" torque wrench and believe it or not it was set at 96 inch lbs from the last time I tightened the bolts.

By the way, my guesstimate of tightness was way off. It was a good 3 full turns of the bolts before the wrench clicked. Well, hopefully it will not leak now.

Thanks for the help guys.

Title: Re: Clutch case gasket, or whatever it is called
Post by Art Webb on 12/12/15 at 18:58:30

Here's hoping no leaky
I need to check my durned old cam chain adjuster

Title: Re: Clutch case gasket, or whatever it is called
Post by springman on 12/12/15 at 19:59:48

Well Art, at least it is easy to do and now you know the torque specs for the cover bolts. Good luck.

Title: Re: Clutch case gasket, or whatever it is called
Post by justin_o_guy2 on 12/12/15 at 20:01:54

You have an inch pounds wrench? You do auto transmission work?

Title: Re: Clutch case gasket, or whatever it is called
Post by springman on 12/12/15 at 20:20:21

Heck no. It was just super cheap at Harbor Freight when it went on sale (around $10) and I figured I would use it on the bike at some point. And I did.

Title: Re: Clutch case gasket, or whatever it is called
Post by Art Webb on 12/13/15 at 08:44:53

Most 1/4 drive torque wrenches are inch lb
the ft lb ones are more rare and pricey
I need to get a torque wrench myself, though I'm pretty good at judging by feel

Title: Re: Clutch case gasket, or whatever it is called
Post by old_rider on 12/14/15 at 16:50:05

7C6F696A787F7F1D0 wrote:

Most 1/4 drive torque wrenches are inch lb
the ft lb ones are more rare and pricey
I need to get a torque wrench myself, though I'm pretty good at judging by feel

Harbor Freight sells both inch lb and ft lb breaker type torque wrenches, I bought them both.
The ft lb is a 3/8 ths and the inch lb is a 1/4 and I think I paid like $19 for each on sale....

http://www.harborfreight.com/catalogsearch/result?q=Torque+wrench

http://images.harborfreight.com/hftweb/home-page2015/images121415/20off121415-coupon.jpg

Title: Re: Clutch case gasket, or whatever it is called
Post by Rodger on 12/15/15 at 19:28:15

If you watch their sale fliers, Harbor Freight occasionally has specials on their "clicker" torque wrenches. I picked up a 3/8" one for $12.

For smaller bolts that only need, say, 8 ft-lbs of torque, I found it easier to set the 1/4" torque wrench to 96 in-lbs. With the 1/4 and 3/8" drive torque wrenches, I'm covered for most cycle stuff, and a 1/2" for automotive work.