LPHRN
YaBB Newbies
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SuzukiSavage.com Rocks!
Posts: 21
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I put off the right rear bolt repair as long as I could.
I followed Dirt Bike Mike's instructions pretty much to the "T", including buying the faucet facing tool. Everything has gone pretty well, with one exception:
For me, the right rear cylinder head bolt was the long one., The "rabbit hole" stud was low enough that I could raise the head high enough to clear it. Not so with the RR stud. I ended up supporting the head with 2 pieces of 2X4, which exposed the center part of the stud.
Using a pair of vice grips and some crocus cloth, I clamped down on the stud as hard as I could. I moved it very carefully, and it did break loose with no slippage. I could only swing it about 1/8 of a turn, so it took a long time to get it finger loose, and then the head came right off.
Now, the problem. Those of you who are familiar with this stud know it has a slight bulge between the threads and the necked-down section of the stud, but only on one end. It appears to be about .6 mm larger than the threaded portion, and on mine it as on the bottom end which threads into the case.
When it was time to reassemble, it was extremely tight. I used the double nut technique, and all I could think about was that I might be tearing up the case threads. I went to the fiche, and saw that the RR stud is supposed to be 203 mm. Mine was about 222.
So, I went to the Suzuki shop and ordered the 09108-09004 stud. When it came in it was 222 mm, identical to the one I already had.
Sigh.
I know a 222 mm stud came out of that hole, but the amount of effort it takes to get it back in gives me pause.
Anyone have any suggestions? Please advise, thank you.
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