SuzukiSavage.com - Broke off a Crank Case Cover Bolt!!!!

NewThumperGuy

Full Member

Offline

Lets Ride!!!!

Posts: 119
Sarnia, Ontario, Canada
Gender: male

Broke off a Crank Case Cover Bolt!!!!
05/09/09 at 06:40:25

Grrrrrrrrrr!
Using a torque wrench too! Its one of the bottom ones by the site glass, will it be ok without?? Put on new gasket and all the others are ok.
I plan on a Verslavy install shortly and will remove and replace then if all is well as is for now? What is the best way to remove the broken peice? Where can I get a replacement? Stealership?

This tensioner check and forward control install is definately making me realize I need to work towards raising my patience level.

Back to top

97 LS650 T

IP Logged

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Broke off a Crank Case Cover Bolt!!!! Reply #1 - 05/09/09 at 07:15:24 You broke one of those?!?! at 8 in-lbs of torque?!?! I replaced mine with a stainless steel kit off of fleabay. If that's not one with an rubber washer, might be ok for a bit. I'll send you my old one's for postage.
Back to top	Versey's Place Tech Section Index IP Logged

NewThumperGuy

Full Member

Offline

Lets Ride!!!!

Posts: 119
Sarnia, Ontario, Canada
Gender: male

Re: Broke off a Crank Case Cover Bolt!!!!
Reply #2 - 05/09/09 at 07:54:31

verslagen1 wrote on 05/09/09 at 07:15:24:

You broke one of those?!?! at 8 in-lbs of torque?!?!

I replaced mine with a stainless steel kit off of fleabay.

If that's not one with an rubber washer, might be ok for a bit.

I'll send you my old one's for postage.

Printed tech section for inspecting, said 10lbs not 8. Wrench did not click the same with that bolt??
Wrote you at your other email requesting a verslavy. Found my plunger out 17mm. Can you throw the bolts in with that package possibly???

Back to top

97 LS650 T

IP Logged

Savage_Amusement Serious Thumper Offline On this steel horse I ride. Posts: 1004 Omaha, NE Gender:	Re: Broke off a Crank Case Cover Bolt!!!! Reply #3 - 05/09/09 at 08:29:01 I twisted a stock bolt out with 5lbs, they are junk. I'm glad I got the kit off ebay. About the only time I thought ahead on something lol. Although there are extras in there that I have NO idea where they go.
Back to top	2K5, 1975 Sportster tank, blacked out motor, K&N cone, Much more to come later!! IP Logged

NewThumperGuy

Full Member

Offline

Lets Ride!!!!

Posts: 119
Sarnia, Ontario, Canada
Gender: male

Re: Broke off a Crank Case Cover Bolt!!!!
Reply #4 - 05/09/09 at 08:44:21

Savage_Amusement wrote on 05/09/09 at 08:29:01:

I twisted a stock bolt out with 5lbs, they are junk. I'm glad I got the kit off ebay. About the only time I thought ahead on something lol. Although there are extras in there that I have NO idea where they go.

What does the kit cost? Who sells them? Maybe I should order before going in again to replace tensioner?
How did you get your bolt out? screw extractor? Need advice on this one.
I'll have the site up all day as I install the forward controls. Turning out to require a little more work then I would have liked but the end result will make it all worth it I hope.

Right side fabbed to fit, polishing exhaust, then onto the left side.

Back to top

97 LS650 T

IP Logged

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Broke off a Crank Case Cover Bolt!!!! Reply #5 - 05/09/09 at 09:12:29 http://cgi.ebay.com/ebaymotors/SUZUKI-SAVAGE-LS650-S40-polished-stainless-bol... Not a bad set, includes every bolt you'll need for the engine. Short the carb screws, but if you ask I'm sure he'll include them.
Back to top	Versey's Place Tech Section Index IP Logged

NewThumperGuy

Full Member

Offline

Lets Ride!!!!

Posts: 119
Sarnia, Ontario, Canada
Gender: male

Re: Broke off a Crank Case Cover Bolt!!!!
Reply #6 - 05/09/09 at 09:37:50

verslagen1 wrote on 05/09/09 at 09:12:29:

http://cgi.ebay.com/ebaymotors/SUZUKI-SAVAGE-LS650-S40-polished-stainless-bol...

Not a bad set, includes every bolt you'll need for the engine. Short the carb screws, but if you ask I'm sure he'll include them.

Just to be sure before asking we need M5 allen head at 10mm and 16mm correct??

Back to top

97 LS650 T

IP Logged

NewThumperGuy Full Member Offline Lets Ride!!!! Posts: 119 Sarnia, Ontario, Canada Gender:	Re: Broke off a Crank Case Cover Bolt!!!! Reply #7 - 05/09/09 at 19:58:31 I must be right if nobody is correcting me.
Back to top	97 LS650 T IP Logged

Savage_Amusement Serious Thumper Offline On this steel horse I ride. Posts: 1004 Omaha, NE Gender:	Re: Broke off a Crank Case Cover Bolt!!!! Reply #8 - 05/09/09 at 23:15:32 I can't remember I went to ace and got all the screws for my carb long before I ordered the kit.
Back to top	2K5, 1975 Sportster tank, blacked out motor, K&N cone, Much more to come later!! IP Logged

Balderdash

Full Member

Offline

Posts: 117
Minnesota
Gender: male

Re: Broke off a Crank Case Cover Bolt!!!!
Reply #9 - 05/10/09 at 22:02:21

verslagen1 wrote on 05/09/09 at 09:12:29:

http://cgi.ebay.com/ebaymotors/SUZUKI-SAVAGE-LS650-S40-polished-stainless-bol...

Not a bad set, includes every bolt you'll need for the engine. Short the carb screws, but if you ask I'm sure he'll include them.

Just got done using that set for a complete job... (replaced the camchain with the one I bought from the group purchase a couple of years ago here)... But I found that the 18 and 19 (from the microfish blow out picture) were about 1/4 inch too long and had to cut them down. But still, converting everything to a 5MM allen wrench looks pretty enough that I decided to leave the chrome head covers off.

Back to top

IP Logged

Hard Corps

Full Member

Offline

Freedom is worth
facing your fears

Posts: 236
Kansas City, Missouri
Gender: male

Re: Broke off a Crank Case Cover Bolt!!!!
Reply #10 - 05/12/09 at 14:52:31

You can always try removing the broken bolt with an easy-out. But be forewarned, easy-outs like to break off, making you even worse off.

Better option is to tap it with a punch, and then use the indent as a guide for a left-hand-twist hardened drill bit. This should bite in and remove the bolt as you drill it out with the drill in reverse.

If there's enough of the bolt remaining above the surface you can try welding a nut on and then wrenching it off.

Sometimes though, none of the above works (or is even feasible).

In that case, take it to a machine shop. They should be able to drill out the old bolt for you. If it doesn't disintegrate, they'll just helicoil/rethread the hole. Should be about a $50 job if you can't do it yourself.

Back to top

Black 2003, Bare-bones, Somewhere along Route 66, Marine Corps Sergeant

IP Logged