Suzuki does seem to spec the use of some VERY soft steel when it comes to their fasteners.

Years ago (another lifetime it seems) I was a maintenance techician in the Air Force.  On some sub assemblies, we had single use fasteners.  You would torque the fastener to recommended specs then secure with a keeper wire.  When it came time for disassembly and inspection, the fastener would be removed, discarded and replaced with a new one.  It didn't matter how the bolt looked.  We never reused a bolt.  A good thing too, since we're talking about mulit-million $$$ aircraft. I can see erring on the side of caution.

I wonder if Suzuki does the same.  We're all back-yard wrenchers.  I don't know of anyone here who is a Suzuki factory trained technician.  I'll bet you that if you were to read the Suzuki maintenance guide, it probably states to replace the cylinder head bolts if the head is removed for any reason.  

I know I will.  When I swap my cam chain later this summer, I'm going to replace all the bolts in the head.  It adds $26.00 onto the job, but knowing I can torque the bolts to proper specs without (reasonable) fear of them snapping is priceless....

Joe, it states that these are for the covers, usually that means side covers.  Best to ask the vendor if also head cover.

What were you doing with the head cover?  Were you torqueing the head bolts or the chrome cover?  I should check the torque on my head bolts since I now have 1000 miles but wonder how much work that is.

I guess I shoulda said I know 1st hand about this.  I bought a set before I did the cam chain with no intent that I would replace the head cover screws.  And at the time no thought about the carb screws either.  But when I did, looked and found no screws were included for that or the carb.  Nice guy thou, I had asked for a few extra's for the side tin's and he threw 'em in.

And I'd recommend the Stainless steel variety, these don't seem to be.

verslagen1 wrote on 05/14/08 at 22:22:30:



V-man,  I am sure you are aware of this but just a tip for those who are not familiar with SS fastners.  There is one key for using them in aluminum.  Make sure you use ANTI-SIEZE or you will hate yourself later!    Fundamentally aluminum and SS don't get along so well in long term close contact.  A good anti seize will deal with that.

Why did you take off the cylinder head cover for the 7500mi maintenance?  You aren't talking about the 2 chrome trim pieces on the sides, are you?

To check the valve clearance, there are 2 inspection doors built into the head cover.  Each are held in by 10mm bolts.  To check the valves, you remove the 2 chrome side covers, then remove the inspection doors.  There is no reason to remove the entire head cover to do the maintenance....

Depending on how deep the bolt was when it snapped, you may be able to get it out with an easy-out, without disassembling the head.  If not, its about a 3 hour job to remove it from the bike and strip it to the cylinder case.

Good luck......

Skrapiron, no I wasn't checking the valve clearance.  I did that a few days ago.  Part of the maintenance is to torque the bolts under the cylinder head and reseal it with Suzuki Bond 1216.  The actual head cover, not just the chrome side covers, must be removed to get to these bolts.  The broken bolt is in a place where I can't get to it with a drill or anything other than a 10mm offset wrench ... so the entire engine must be removed.  :'(  So ya know what, I'M LEAVIN' IT IN THERE!!  It's deep enough to where I don't think it will vibrate out and there are 8 or 10 other bolts holding the head cover on.  It's just not worth all that work to me--not to mention I'll probably screw up something else while attempting to remove the engine.

Keith, no they weren't out of spec.  It was all for nothing.  Figures.