You may have noticed that, in the above post, I did not consider torquing the bolt that goes in the top left hole in the pictures.

This is because that bolt is also used to secure the left decorative chrome head cover.  With that cover in place, some of the other head cover bolts would be hard to access.

However, if you don't mind going through a little extra trouble, you can torque the head cover in a more complete fashion.

Here is what I used to take the place of the decorative head cover - a stack of washers:





I just placed a bunch of washers on the bolt.  This allowed me to torque the bolt down properly.

After the gasket sealant used on the head cover was cured, I removed the washers and installed the left decorative chrome head cover.


Here is the torque order I used with the extra bolt in play:





IHTH someone!

verslagen1 wrote on 09/12/10 at 18:39:37:



Ver,

Re that diagram:  I've always wondered what they mean by "Yellow bolt" in the text on the right.

Also, in that same text area, is "L75 : Chroming bolt."  Try as I might, I can't find a 75mm-long bolt in the diagram.

Ideas?

I am trying to renew the head gasket and the gaskets under the head cover as well as this plug cap to stop leakage down the left cylinder fins.  

Was hoping to be able to do without taking entire engine out of the frame, but am having trouble getting the head cover off the head due to low frame clearance.  I'm thinking that if I loosen and remove the bottom front three frame bots, that might allow me to let the engine swing down and inch or so between the frame,and give me the extra inch I need to slide the head cover off the valve train.  Anyone tried this as an alternative to pulling the engine?  (By the way, my frame is more basic, as this is a Ryca Cafe conversion)

Thanks for the frank advice.  You know I didn't want to hear that!  The engine has been out before, when I did the Ryca conversion.  It is hard to get out of the frame without scraping the frame, and that is my primary reason for not wanting to remove it, I have a nice new paint job on the frame.  Second, I find it really annoying that they'd make a single cylinder motorcycle that wont'd allow the head to come off without pulling the engine.   Rocket

Off topic replies have been moved to this thread.

terpfan1980 wrote on 10/06/13 at 17:23:05:


That red color is the sealant that has not yet been cleaned off after the head cover was removed.  The sealer needs to be removed, the parts cleaned, and new sealler applied before assembly.  I recommend you buy the correct Suzukibond...but others have used RTV gasket products succesfully and saved a few bucks.

A very thin bead is all that is required.  If you looked at the factory job, you saw very little had squeezed out.  The sealing is done by the mating of the surfaces.....not by the goo that squeezes out.  You put in too much sealer and you can also squeeze out stuff into the internal oil passages that feed oil to the cam......and then it will fail.

Nothing screams....."I have been worked on by an amateur" as much as a glob of orange or blue goo sticking out of the seams does.  Don't do this: