SuzukiSavage.com - Down for a while! Back up again!

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Down for a while! Reply #15 - 09/02/08 at 11:54:41 SavageWahine wrote on 09/01/08 at 22:02:36: 1-use needlenose pliers to hold nut through fins 2-remove cable that goes to solenoid 3-loosen nuts that hold cable 4-pull off cable from head You use these pliers to hold the head of the bolt that holds the chrome head covers on. On the other end is an acorn nut.
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SavageWahine

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Re: Down for a while!
Reply #16 - 09/02/08 at 12:00:56

I need to invest in a good bright flash light!!!
With my engine painted black it even harder to look into that crevice.
Did not see the bolt move up and down however. I'll clean up the area and run her again in a while.

T-Mack, what exactly will spraying the bolt with W-40 do?
You're talking about helping with the ease of removal?
I think I will try a quick fixer method at the moment.
I'll do a better job in the future when I can afford it.

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You take the blue pill the story ends, you wake up in your bed and believe whatever you want to believe.
You take the red pill, you stay in Wonderland and I show you how deep the rabbit hole goes.

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T Mack 1 - FSO

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Re: Down for a while!
Reply #17 - 09/02/08 at 12:11:23

SavageWahine wrote on 09/02/08 at 12:00:56:

I need to invest in a good bright flash light!!!
With my engine painted black it even harder to look into that crevice.
Did not see the bolt move up and down however. I'll clean up the area and run her again in a while.

T-Mack, what exactly will spraying the bolt with W-40 do?
You're talking about helping with the ease of removal?
I think I will try a quick fixer method at the moment.
I'll do a better job in the future when I can afford it.

I think you will find yourhead cover bolts frozen tight. The WD-40 will help free them up a bit. As Verslagen said, the bolt can snap.

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Engineers design things, Technicians make them work.
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30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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SavageWahine

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Re: Down for a while!
Reply #18 - 09/02/08 at 13:16:52

I'm pretty sure now that this is the culprit.
Used Greg's image in his tech forum.

I cleaned up the area and ran the bike for 5 minutes.
It was totally covered in oil again.
I'm going to have to think about this for a while.
If it takes you guys about 3-4 hours, it'll take me about twice that long if not more. I'm a little slow cause I keep on double checking myself afraid to make a mistake.
And what seems logical to someone does not always seem logical to me, so you got to add the time it takes for me to wrap my head around a concept first before I even tackle it.

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You take the blue pill the story ends, you wake up in your bed and believe whatever you want to believe.
You take the red pill, you stay in Wonderland and I show you how deep the rabbit hole goes.

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T Mack 1 - FSO

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Re: Down for a while!
Reply #19 - 09/02/08 at 13:29:39

Oil there means the culprit is 95% the plug.... (probably 100% but I'm leaving room for other odd things)

The hardest part is loosening the bolts, second is rotating the cover so it clears the frame.

Remember, cardboard with sketch of the cover. As you take the bolts off, push them thru the corresponding spot on the sketch.

Remember to clean the surfaces where the cover matches up with the head. The gasket gook need oil free surfaces to work properly.

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Engineers design things, Technicians make them work.
---
30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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SavageWahine

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Re: Down for a while! You're not going to believe
Reply #20 - 09/02/08 at 15:24:12

Okay!!!
Couldn't focus on the job I'm supposed to do (I hate it shouldn't ever have taken this one) so I started messing with the bike.
Put it on the poor gal's bike-stand and got the tank off etc.
took the left side chrome cover off (W-40'd for sure) and looked inside.
Bunch of oil piled up in there and dirt.
Looked again there was something lying in there. A huge bolt!???
How did that get in there, no idea. The I figured it had to come from somewhere so I looked around. I saw the engine mount bracket thingy and noticed that there was an empty hole in there about the size of the bolt.................
Looked on the other side of the bike, and what do I see......a nut! Fits on bolt....
It took me a few seconds to realize that I was looking at the bolt that is supposed to hold the top of the engine on the frame. Well. the hole on the engine that the bolt goes through does not line up with the hole in the bracket anymore. By the looks of it , it has been off for quite a while seeing the bracket hole is rusty.
That might give me some problems I guess.

I'm not quite sure what is meant by step 2, 3 & 4.
The solenoid is on the right hand side the only cable I see is the electrical one.
Is that thing on the left part of the solenoid?

2-remove cable that goes to solenoid ??
3-loosen nuts that hold cable???
4-pull off cable from head
5-remove spark plug wire from plug

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You take the blue pill the story ends, you wake up in your bed and believe whatever you want to believe.
You take the red pill, you stay in Wonderland and I show you how deep the rabbit hole goes.

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Demin Serious Thumper Offline We need more chlorine in the gene pool Posts: 2435 Warren,Ohio Gender:	Re: Down for a while! You're not going to believe Reply #21 - 09/02/08 at 16:02:40 Ok,I'll sacrifice myself Get me a ticket there,and I'll fix it for free.
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SavageWahine

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Re: Down for a while! You're not going to believe
Reply #22 - 09/02/08 at 16:58:30

Demin wrote on 09/02/08 at 16:02:40:

Ok,I'll sacrifice myself Grin

Get me a ticket there,and I'll fix it for free.

HMMMM something tells me that having the dealer fix it will be cheaper then buying you a ticket! LOL (not that I wouldn't love to meet you!)

I finally figured out what I'm supposed to do but I need to borrow one of those power screwdriver (forgot the name) because those are Philips head screws and I tried to loosen up one and it started shredding the head a little so I'm leaving it alone till I get one of those power things.
I am worried about number 16
DO NOT REMOVE THE BOLT that is on the right side
closest to where you removed the big tube
can't figure out which bolt he is talking about.

is it L25 or c25?

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You take the blue pill the story ends, you wake up in your bed and believe whatever you want to believe.
You take the red pill, you stay in Wonderland and I show you how deep the rabbit hole goes.

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Max_Morley

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Re: Down for a while! You're not going to believe
Reply #23 - 09/02/08 at 17:10:21

Hand held impact wrench or in the Japanese translation "attack driver". Sears usually has them, I like the 3/8 drive size best, 1/2 will work. You twist it the way you want to turn the screw/bolt/nut and then smack it with a decent size hammer. It drives the bit into the mating holes in the screw head and turns it. Usually one or two smacks does it. Max

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Max at Thumper Acres. '96 Savage bagger, '03 Savage w/Cozy sidecar for wifeni.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Down for a while! You're not going to believe Reply #24 - 09/02/08 at 17:14:28 s30 is the one you don't remove. impact driver the cable to remove is like the clutch cable on the left side and attached to a lever on the head, real loose. Yep, I twisted off that screw when I did mine too. I've wondered, can you push that plug up from the bottom and pull it out?
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SavageWahine

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Re: Down for a while! You're not going to believe
Reply #25 - 09/02/08 at 17:21:30

verslagen1 wrote on 09/02/08 at 17:14:28:

s30 is the one you don't remove. THANKS it's still on

I've wondered, can you push that plug up from the bottom and pull it out?

I think I might try that myself and leave the solenoid cable attached.
Maybe just tip the right side up and see if I can get to the plug.
I forgot who but someone else did it that way too.

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You take the blue pill the story ends, you wake up in your bed and believe whatever you want to believe.
You take the red pill, you stay in Wonderland and I show you how deep the rabbit hole goes.

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T Mack 1 - FSO

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Re: Down for a while! You're not going to believe
Reply #26 - 09/02/08 at 18:48:50

SavageWahine wrote on 09/02/08 at 17:21:30:

verslagen1 wrote on 09/02/08 at 17:14:28:

s30 is the one you don't remove. THANKS it's still on

I've wondered, can you push that plug up from the bottom and pull it out?

I think I might try that myself and leave the solenoid cable attached.
Maybe just tip the right side up and see if I can get to the plug.
I forgot who but someone else did it that way too.

Leave the cable on the bracket!!!!! Take bracket off the headcover, two philips screws.....

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Engineers design things, Technicians make them work.
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30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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SavageWahine

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Re: Down for a while! You're not going to believe
Reply #27 - 09/02/08 at 19:19:49

Okay....
Is there anything amiss with what you see?

There was only one small rubber seal on the whole engine part, except for head plug end big round rubber plug, and that was the one around L30.
According to the printout with the bolt locations L16, L70, L60 and L55 have gaskets, but there were none on mine.
What exactly is the head seal? that big rubber plug?
both plugs look in good shape however, no deterioration or punctures or anything.

I did end up shredding one of the philips head screws even with the impact drill, and ended up dremeling the head so that it would hold a size 3 philips. Then I used the impact drill again to get it off. I got lucky!!

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You take the blue pill the story ends, you wake up in your bed and believe whatever you want to believe.
You take the red pill, you stay in Wonderland and I show you how deep the rabbit hole goes.

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SavageWahine Serious Thumper Offline Aloha & Hang Loose Posts: 1553 Beautiful Kauai! Gender:	Re: Down for a while! You're not going to believe Reply #28 - 09/02/08 at 19:32:20 Does anyone know where this little o-ring came from? There wasn't one on my engine. Greg's image:
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Down for a while! You're not going to believe Reply #29 - 09/02/08 at 20:12:56 The figure 8 o ring on the head cover?
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