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Savage "Plug/Cap" Leak (Read 13863 times)
Savage_Greg
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Re: Savage "Plug/Cap" Leak
Reply #30 - 03/21/07 at 13:25:48
 
w6k wrote on 12/31/69 at 16:00:10:
       I always use a product called Never sieze on the head bolts. It allows them to torque down without binding and makes them easier to remove also. Much less likely to break one off.

Have you ever seen the instructions in the SSM?  I was surprised when I read it...

They tell you to use a drop of oil on each stud when torquing the nuts.  It works too.  The idea is to lube the nut and copper washer so they will sort of "settle" into place without galling when torqued.
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Re: Savage "Plug/Cap" Leak
Reply #31 - 03/22/07 at 08:12:16
 
Yep, tha's called "wet" torque as oposed to "dry" torque.
Wet gives you a more precise torque value as the frixtion of the thread and washers is less.

From the B757 MM. Cheesy
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Savage_Greg
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Re: Savage "Plug/Cap" Leak
Reply #32 - 11/13/07 at 15:02:15
 
I'm adding this note to this topic as a warning.

I know that we are often tempted to use different sealants, but Do Not Use the "MotoSeal® 1 Ultimate Gasket Maker Grey" sealant when installing the headcover.  
 
I picked up this stuff at Shucks Auto Supply (Parts America) and may be available at Auto Zone, etc too.  It claims to be specifically designed for bikes and watercraft.

I tried this stuff as an experiment because it is easy to apply.  It may work on engine cover gaskets, but it will not seal the headcover.  It becomes hard and begins leaking fairly soon.  

Using the High Temp RTV (or Suzuki Bond) is still the best sealer to use.

PS - Rob has informed me that the Permatex® Ultra Grey® Rigid High-Torque RTV Silicone Gasket Maker works just fine, so don't confuse the 2 sealants because the names are similar.
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Re: Savage "Plug/Cap" Leak
Reply #33 - 11/15/07 at 12:37:32
 
"MotoSeal® 1 Ultimate Gasket Maker Grey"  
 
It's claim to fame is being gasoline proof once cured - say on the older carbs where the drain plug removes - if you strip that out this will do a reasonable job sealing it up.
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Savage_Greg
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Re: Savage "Plug/Cap" Leak
Reply #34 - 11/16/07 at 09:18:34
 
Reelthing wrote on 12/31/69 at 16:00:11:
"MotoSeal® 1 Ultimate Gasket Maker Grey"  
 
It's claim to fame is being gasoline proof once cured - say on the older carbs where the drain plug removes - if you strip that out this will do a reasonable job sealing it up.


Maybe, but not on the headcover.  Every bit of mine began leaking all the way around (I had all kinds of oil woes, didn't I?)...it is also harder to remove than the RTV type.
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Re: Savage "Plug/Cap" Leak
Reply #35 - 06/25/08 at 20:04:55
 
I also would not recommend ThreeBond Liquid Gasket 1104.

It seals good (the guy at the Suzuki dealer recommeded it), but it's a real bear to remove.

I have had good luck with the Permatex Ultra Copper

It's never let me down!
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Savage_Greg
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Re: Savage "Plug/Cap" Leak
Reply #36 - 07/30/08 at 09:18:51
 
I'm happy to say that I've got about 2K on my last rebuild (new piston, rings, etc) and I just changed to a synthetic oil with the new break-in, too.  

I used a high temp RTV sealer that was black this time.  The entire head cover and plug are dry.  Not a drop...
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Re: Savage "Plug/Cap" Leak
Reply #37 - 04/08/09 at 17:41:17
 
While in doing this is it also a good time to get a new cam chain and install it? Or does it need to be torn down further yet?
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Re: Savage "Plug/Cap" Leak
Reply #38 - 04/08/09 at 17:58:08
 
All you got to do is take the primary gear off (one big ass bolt)
and the cam sprocket off (2 little bolts)
to get the chain from here.
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Re: Savage "Plug/Cap" Leak
Reply #39 - 04/20/09 at 11:13:02
 
I just did this fix hoping that it was my plug cap that was leaking.  Got all the bolts out no problem and the head cover came off with minimal prying.  Sure enough, the plug cap was the old style-like a cup and came was just sitting there over the hole.  It was sort of thingy-eyed and I could even see the head cap nut under it next to the exhaust port by looking down!!  Needless to say, I put a layer of silicone sealer on the new one and hammered it into place w/ my trusty rubber mallet.  That thing AINT leaking anymore!  Everything went back on correctly but I still need to do a valve adjustment and adjust the decomp solenoid before I fire it up.  

p.s.  Best piece of advice I could give anyone attempting this fix is to just go for it and be thorough!  The paper template of the bolts on the head cover taped to a cardboard box worked perfectly and none were mixed up going back in.  I didnt see any signs of bolts snapping off, mainly cuz it looks as this was the first time the head cover had EVER been removed from my bike!  It also helps to have small hands and my rather large hands made getting a few of the bolts in and out kinda difficult, but got it done none the less.

-Matt
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Re: Savage "Plug/Cap" Leak
Reply #40 - 04/20/09 at 13:41:22
 
Also another quick piece of advise may be to give the reassembly a couple of dry runs before you put any sealer on it. That way you will know which bolts will need to be installed before you put it back on. (meaning if your doing it while the motor is still on the bike) There is one in the middle on the top that is long and it has to be in there before you put it back on or there isn't enough room.
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Re: Savage "Plug/Cap" Leak
Reply #41 - 04/20/09 at 14:05:39
 
Yup, that bolt in the middle has to be in there before you put the cover back on the head or else it wont fit.  I made the mistake of forgetting to put the oil breather screen in the cover when I put it back on the first time.  The sealant got a little smeared when I pulled it back off but I think it sealed it up fine when I torqued it down after putting the screen back in.  Another trick is to use a nickel along with a pair of vice grips to get the timing plug out of the left side stator cover.
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Re: Savage "Plug/Cap" Leak
Reply #42 - 06/21/09 at 17:18:46
 
So I did not bother with TDC because I was not touching the timing chain or any of the valves, right? So I replaced the plug w/sealer and put everything back together.  Now, when I try and start the bike the starter turns the motor over but will not say run by itself.  I engine is getting fuel as far as I can tell (I pried it).  Any thoughts, or am I better just trying again? thanks
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Digger
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Re: Savage "Plug/Cap" Leak
Reply #43 - 06/21/09 at 22:15:33
 
FYI:

Here is the P/N of the new style plug:





Here is a top view of the new plug:






Here is a bottom view of the new plug:




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Digger
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Digger
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Re: Savage "Plug/Cap" Leak
Reply #44 - 07/09/09 at 20:42:23
 
Just for comparison's sake, here is what the old-style plug looks like (the plug in the photos is used, and has some residual copper-colored gasket sealant on it):









IHTH someone!
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Digger
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I don't own a cage.
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