SuzukiSavage.com - head cover questions

vhfkid

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head cover questions
05/25/09 at 15:35:45

Ok, I did the cap/plug leak and found it only leaking a little, but lots was leaking out from a bad seal with the old black sealant.

I made two mistakes, first I took out the "screw/bolt" that holds in the exhaust rocker shaft. I tried so very hard not to remove it, but I think in the hot Texas sun I was loosing my mind

Anyway it bolted right back in, and the rocker arms line up just right for the tappets. Is the shaft threaded and do I really need to pull the cover again for this one?

The second issue, upon putting all the bolts into the holes after the silicone got tacky, one of the holes had a bit of machined metal partially blocking the bolt from going down. I have no idea what piece of metal it was, but it was machined and was near the cam on the intake side of the cam, near the right side rear chrome top cover bolt.
I suspect it was not loose, but attched to someting, everything torqued down strait. Any ideas on this one too from those more experienced with this engine?

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diamond jim

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Re: head cover questions
Reply #1 - 05/25/09 at 16:56:34

Part of the rear upper chain guide?

Another tip in the future. When using the anti-seize, I suggest dabbing some on a q-tip and using that to rub a little in the threads of the head as opposed to applying it to the bolts then inserting. Here's why although it might not be a big concern. I did the "put anti-seize on the bolts and insert method" the first time. Did the bolts finger tight. Looked around and saw my plug sitting next to my bike. Crap! Took off the cover again and found anti-seize mixed in with oil around the cam/cam journal sections. Apparently when I inserted the bolts, even though I didn't put a lot of anti-seize on the bolts- just enough, when the bolts found the screw holes and started going in the anti-seize seemed to catch on the thread opening, move horizontal and blend with the oil. This was mainly that bolt that, when on the seat and looking down, is at the left rear of the cam, really close to the cam itself. Likely not a problem to have anti-seize there but I just don't want oil polluted with anti-seize trapped between the cam/cam journals when I start it up the first time afterwards.

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vhfkid

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Re: head cover questions
Reply #2 - 05/25/09 at 18:04:07

I know that bolt! mine was soaked in oil too. I cleaned out the hole as best I could. I didn't use antisneeze, only oil, as another trip to the parts store was putting me behind, now that I think of it I wouldn't want antisneeze in there either Shocked

I had gone to the store before to get the right size feeler gauges (lost mine in the last move), and the 30° ones only had .005, not .003 and .005, like the other non angled set had.

Much of my oil leaking was in front of the spark plug and on the other side of the cam journal.

I'm praying I don't have to pull it apart again. I'm not sure if I should. It was a lot of work getting it all off and then getting it all back in! I was very glad I didn't have to take the engine out though!

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vhfkid Full Member Offline Thumpin' in ETEX Posts: 138 East Texas Gender:	Re: head cover questions Reply #3 - 05/25/09 at 18:46:27 Here is the bolt hole where I had to move a machined piece out of the way to insert the bolt. If anything were to move would it be the intake rocker arm shaft? They seem to be in the same line.
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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: head cover questions Reply #4 - 05/26/09 at 01:03:02 Only one rocker shaft is locked down by a bolt the other is held in place be the big bolt in from the side. It may be that the shaft bottoms out on that bolt and you might just have to back it out to clear it.
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vhfkid

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Re: head cover questions
Reply #5 - 05/26/09 at 11:20:48

verslagen1 wrote on 05/26/09 at 01:03:02:

Only one rocker shaft is locked down by a bolt the other is held in place be the big bolt in from the side. It may be that the shaft bottoms out on that bolt and you might just have to back it out to clear it.

yeah the exhaust shaft is held down, but is the shaft threaded, or does it just have a hole?

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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: head cover questions Reply #6 - 05/26/09 at 11:42:10 vhfkid wrote on 05/26/09 at 11:20:48: yeah the exhaust shaft is held down, but is the shaft threaded, or does it just have a hole? Manual shows no hole at all in the shaft.
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vhfkid

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Re: head cover questions
Reply #7 - 05/26/09 at 12:48:22

verslagen1 wrote on 05/26/09 at 11:42:10:

vhfkid wrote on 05/26/09 at 11:20:48:

yeah the exhaust shaft is held down, but is the shaft threaded, or does it just have a hole?

Manual shows no hole at all in the shaft.

On the online fiche
http://www.scoot.bg/arhiv_na_opisanie_motori/650cc%20(LS650K5-7%20NP41A%20200...

Page 9, part 14 shows the exhaust shaft. I did remove the bolt that holds it in. I put it back in after I had the cover back on, but I'm not sure if it's actually holding it in, but if that shaft is threaded, then it is holding it in.

I'm mostly concerned about what was blocking the hole in the picture a few posts back. I pushed it out of the way (along the same axis as the intake shaft). I have no Idea what I pushed out of the way! It was machined and looked to be just a bit bigger than the diameter of the bolt. The machining looked kinda like a cam lobe, but it was so hard to tell in that small hole.

Any ideas? I'm running out of time to get my bike ready for our trip. If I have to pull it off again I will, but I'm getting over a cold and still have to get the wife's exhaust leak fixed.

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