SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> new oil leak, not the head plug leak /cgi-bin/YaBB.pl?num=1597926582 Message started by rawsavage on 08/20/20 at 05:29:41

Title: new oil leak, not the head plug leak Post by rawsavage on 08/20/20 at 05:29:41 Hey Guys, out of nowhere one of the top head bolts is starting to leak. i allready swapped out a new copper washer, it did work for a bit and now it started to leak again.. i can see it pooling below the bolts head, i cannot tighten the bolt more. (it will simply not bottem out) the leak started out of nowhere, i haven't worked on the engine/top head. (the headplug is not the problem, i fixed this half a year ago with the new solid version) Thanks in advance guys!!

Title: Re: new oil leak, not the head plug leak Post by DragBikeMike on 08/20/20 at 11:59:01 That bolt passes through your oil feed passage.  It is pressurized.  If the bolt won't tighten, the threaded hole in the cylinder is probably stripped. Repair will require removal of your engine. I had a similar bolt hole strip on my 97mm project.  I fixed it by drilling through and installing a 1/4-20 grade-8 bolt & nut.  You can’t do that on this one without fouling the oil feed with debris.  But once the head is removed, you could drill through and clean up the debris.  I believe you could seal up the lower side similar to the top side.  Seal washers and ample sealant should do the trick. I suspect you will develop a leak at the head gasket too.  Look below the bolt, into the joint between the head & cylinder.  That bolt provides the clamping force in the critical oil feed area between cylinder & head.  If it’s not already leaking there it will probably start soon.

Title: Re: new oil leak, not the head plug leak Post by justin_o_guy2 on 08/20/20 at 12:59:51 Pray you got the wrong bolt in that hole and it is really too short.. Be honest,, when you were goin back together, did ya feel the required torque drop in the last half a turn? Id pull the bolt take a piece of wire and find the bottom of that hole measure that depth,, mark the wire see if the wire is longer than the bolt Hope like hellll it is,, by at least the diameter of the bolt, longer. Then Id heat the washer to glowing and drop it in water get a longer bolt,, and Go Back Very gently,, and use a very finely applied bit of the right sealer,, not RTV,,

Title: Re: new oil leak, not the head plug leak Post by verslagen1 on 08/20/20 at 13:00:13 shouldn't be a copper washer, it's a sealing washer, rubber coated.

Title: Re: new oil leak, not the head plug leak Post by justin_o_guy2 on 08/20/20 at 13:42:13 Daaaayumm,, forgot about that,, Yeah.. what he said.. Still think you should try to go longer,, on the bolt,,

Title: Re: new oil leak, not the head plug leak Post by verslagen1 on 08/20/20 at 14:19:42 If your bolt is stripped, try a new one or a slightly longer one. may save you from putting a helicoil in.

Title: Re: new oil leak, not the head plug leak Post by Dave on 08/21/20 at 02:12:24 The washer should have a rubber seal on the inside......if that rubber is damaged or old and brittle it could also allow a leak. You could try cleaning everything up and place a small amount of sealer under the bolt when you put it back in.

Title: Re: new oil leak, not the head plug leak Post by justin_o_guy2 on 08/21/20 at 11:41:02 i cannot tighten the bolt more. (it will simply not bottem out) Slightly disconcerting

Title: Re: new oil leak, not the head plug leak Post by rawsavage on 08/22/20 at 06:40:43 Thanks guys for all the replies! I did feel the drop when getting it on torque, When i did the oil plug upgrade i did print out the template, so i could stick all the bolts on the right spot with the cardboard trick.. I measured the bolt and it is the correct L130 one.. nuts, sounds logic with the copper ring instead of gasket ring, will try it!! “ i cannot tighten” Haha, understand this sounds concerning, but i was not trying to gorilla grip it, it will simply won’t reach a point where you feel the slightest pressure Thanks guys! Love this forum and have been lurking for years here. Will try i slightly longer bolt, with the correct coated seal ring! If it won’t work i will go the helicoil route...

Title: Re: new oil leak, not the head plug leak Post by rawsavage on 08/22/20 at 07:10:45 Okay, i rechecked the bolt. No bueno.  2 thread holds some inside of the engine, so i think the thread inside the engine is shot. (The threads on the bolt are not stripped) Am i totally screwed now, or is the slightly longer bolt still worth a shot? Or should i allready go the helicoil route? (After the camchain tensioner mod, the oil plug upgrade i was hoping for some trouble free milages haha.)

Title: Re: new oil leak, not the head plug leak Post by justin_o_guy2 on 08/22/20 at 07:31:52 is the slightly longer bolt still worth a shot? You have to determine that Wire Measure depth Compare to your bolt Is the hole deeper enough to get a longer bolt in it? If threads go down another distance equal to the bolt diameter, youve got a shot. If ya cant Buy a Bolt the exact length to use what threads ya have, get one too long put a nut on it, cut it to length, remove the nut, and the threads are straightened up.. When tightening stuff, dont think about Tightening Youre creating a Clamping Force,, Every bolt involved in that needs to be used with the others equally, all thru the torquing process,, Its much better to spend too much time getting something put together because instead of running a torque pattern twice you decided to incrementally increase torque by running the pattern five times,, Its easier to fix a leak later than repair something stripped or twisted off.. Once the bolts have landed and the mating surfaces are in full contact, youll FEEL the bolts. Thumb on 1/4" ratchet head, open fingers on handle, closing fingers slowly, making a fist,,no torque wrenc required here.. Inexperienced people shuld go buy some bolts and whatnot, Put something in a vise, run a bolt thru, feel what a bolt feels like,,just before it dies,, Feel what it does when parts are fully clamped,, I wish someone had told me to do that when I was a teen.. Its not a race You win by not building yourself a beartrap OHH,, IF youre running a pattern and get to a bolt that says its done turning DONT try to get another 1/4 turn on it,, go on with the pattern,

Title: Re: new oil leak, not the head plug leak Post by ohiomoto on 08/22/20 at 11:56:49 rawsavage,   I really like your simple, slightly ratty, and a little old-school style chopper.  It's really cool without trying too hard if you know what I mean.  Well done!

Title: Re: new oil leak, not the head plug leak Post by Dave on 08/23/20 at 03:45:16 You are not the only one who has ever had this problem. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1562996383/0#0 I helped one of our members who was local to me with a repair using a threaded rod to replace the bolt.  The threaded rod was a bit longer than the stock bolt, and I had slightly tapered and cut two grooves in the end of the rod to help cut new threads.  I used a 6mm barrel nut with a short screw on top to allow me to turn the rod as it was being installed.  I first installed the rod until it got snug, then gave it a 1/16th turn and gave a firm tap with a hammer, then continued until the threaded rod was pretty snug.  The stud has to be just long enough that you can install the sealing washer and an acorn nut on top to get things sealed.  It worked on this engine.......the member never really was too active after that thread and never gave a long term report. (Unfortunately the photos that were posted on TinyPic are gone and I don't believe I kept the original ones). Trying to install a helicoil repair with the engine together is likely impossible, especially since this is an oil passage and any shavings left in the hole could move up into the head cover where they will get to the cam/rockers.

Title: Re: new oil leak, not the head plug leak Post by rawsavage on 08/23/20 at 05:10:13 Thanks guys! Justin i will check the depth with a wire, and i will go on from there. Thanks. Haha i understand ohio, thank you! The ports are slightly enlarged, rejetted carb etc. The sissy bar i twisted myself With the help of a forging fire.  the horrible airbrush devil job on top of the tank is from the original owner, but i started to like it (it had a nice cracklin patina) , i just took gold markers for the savage on the side haha. Dave, thanks! Good to know, this trick might come handy, that’s some solid advice! Will keep you guys posted!

Title: Re: new oil leak, not the head plug leak Post by ohiomoto on 08/23/20 at 06:20:29 I am not a fan of most airbrush work (too juvenile) and you're right, it is horrible!!  But that's the beauty of your bike.  Woking with what you got and somehow making it cool.  People do far less with much more.  haha

Title: Re: new oil leak, not the head plug leak Post by rawsavage on 08/23/20 at 08:30:21 Haha Amen Ohio! I hated it at first, was planning on making it into a “clean” chopper, But then it started to grow on me haha. It does get alot of attention when we’re visiting bike shows from the Ol chopper lovers. (I’ve a crankcase breather from a southern comfort bottle etc)

Title: Re: new oil leak, not the head plug leak Post by justin_o_guy2 on 08/23/20 at 08:36:05 Justin i will check the depth with a wire, and i will go on from there. Thanks. Go back and read how Dave did it.. Yeah,, discover the depth, however you must, but I sure like his solution. Ahh,, my ability to REad a word without any thot has changed over the last few decades,, I hafta admit, I STILL see your name and misread it..

Title: Re: new oil leak, not the head plug leak Post by rawsavage on 08/23/20 at 08:47:54 Yeah thanks Justin, Will use the advise that’s given! So much knowledge here, really appreciated!!

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