SuzukiSavage.com - Houston, I have problems!

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Houston, I have problems!
01/06/12 at 14:10:39

Well, for you guys today I have three problems that I need help with: Two oil leaks and a brake rotor/caliper problem. All help is appreciated!

Number one: I have an oil leak coming from the front of the bike it seems, as seen here:

This goes around the side like so (although I think it;s just runnage from the front that I haven't cleaned Grin

)

Also, I have a leak near my spark plug as seen here and here:

http://imageshack.us/g/31/plugleak.jpg/

AND last but not least, I'm having a problem with my rotor touching my caliper, which is causing wear and surface rust on the rotor, along with slight squeaking:

Thank you all in advance for any help you may have for me! I can't wait to get back to riding... Sad

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verslagen1

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Re: Houston, I have problems!
Reply #1 - 01/06/12 at 15:02:24

leaks coming from that nut are generally the head gasket, you can tighten it up and sometimes it goes away.

leaks around the sparkplug are from the head cover or the head plug, both require removal of the head cover to fix.

and last, caliper touching disk, not good, either your pad is worn out or you've assembled the caliper on fork incorrectly. there shouldn't be any washers between the fork and caliper.

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UndefinedHero YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 11	Re: Houston, I have problems! Reply #2 - 01/06/12 at 15:21:49 I guess I need to do some wrenching, then. When I have time, that is. How much is fixing those leaks gonna cost if I do it myself, roughly? I just replaced the pads, so they're not worn out. The previous owner has put two washers on each bolt that goes into the fork and caliper. Could that be it?
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MotoBuddha

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Re: Houston, I have problems!
Reply #3 - 01/06/12 at 15:38:11

The caliper slides back and forth on two post -- providing the posts are clean and properly greased. Yours might be stuck. To check, unbolt the caliper from the fork and see if the caliper will slide easily back and forth on the mounting bracket.

And, get rid of the washers if they were between the caliper bracket and the fork. They're okay if they were between the fork and the bolt heads.

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UndefinedHero YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 11	Re: Houston, I have problems! Reply #4 - 01/06/12 at 15:42:36 It slides fine. But that has nothing to do with the part that bolts to the fork touching the rotor.
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28637 Tucson Az Gender:	Re: Houston, I have problems! Reply #5 - 01/06/12 at 15:47:14 Head plug is $10.00,... the rest is just turning wrenches...
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verslagen1

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Re: Houston, I have problems!
Reply #6 - 01/06/12 at 15:50:46

moto the part that gets near the disk is immobile
putting washers between it and the fork will shift it out
there's normally 2 washers, at least 1 should be under the head of the bolt. you can use the extra to space the caliper out if it's close.

you only need rtv to seal up the head plug and head cover.
there's a 8 shaped oring between the head cover and head too.
most will replace the plug and oring, but not always necessary.

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UndefinedHero YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 11	Re: Houston, I have problems! Reply #7 - 01/06/12 at 16:39:34 I don't see any way to space the caliper out. When I put it on, the part that has the bolt-holes is already squeezed between the fork and the rotor.
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UndefinedHero YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 11	Re: Houston, I have problems! Reply #8 - 01/06/12 at 16:50:51 If I put washers between the fork and the caliper, then the caliper will be touching the rotor even more, which is quite impossible lol
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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: Houston, I have problems! Reply #9 - 01/06/12 at 17:03:22 Ok, another thing... our pad comes in 2 sizes, the thinner pad is for the savage the thicker for some atv. you may have the wrong pads. if one of your old pads still has any meat on it, use it with one of the new ones till it's worn down some.
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UndefinedHero YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 11	Re: Houston, I have problems! Reply #10 - 01/06/12 at 17:07:02 The pads are pretty thick. But when I took the pictures, I put the caliper on without any pads and they still touched. I'm at a loss here with what could be wrong. It seems like the fork needs to come out a bit or the rotor needs to move in
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Routy

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Re: Houston, I have problems!
Reply #11 - 01/07/12 at 05:14:17

It should be obvious as to what has to be done to correct the cal/rotor problem.

Could axle spacers be in the wrong place ? Does the rotor need spacers to move it over a little ?

Just guessing,....as I'm 1200 miles away from my bike. But I think I would look at the spacers on the axle, and do "whatever" to move the fork away from the wheel/rotor

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Rich
'07 S40 Blvd stocker, except drilled OEM exhaust and white spacer mod...1/2 (.055)

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MotoBuddha

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Re: Houston, I have problems!
Reply #12 - 01/07/12 at 06:28:34

Routy wrote on 01/07/12 at 05:14:17:

Could axle spacers be in the wrong place ?

If it's the original caliper mount, and if there are no washers between the fork and the bracket, then it's probably that the axle spacers are swapped. The one on the brake side of the wheel should have a small lip on the end that touches the fork. Without that lip, the whole wheel-rotor assembly will be too close.

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UndefinedHero YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 11	Re: Houston, I have problems! Reply #13 - 01/07/12 at 08:26:24 Well, I checked, and I see that there is indeed a lip on the wrong side if you are correct. There is a metal spacer with a lip on the right side of the wheel. The left side spacer has no lip.
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Houston, I have problems! Reply #14 - 01/07/12 at 08:48:39 See parts 6 and 5 below.
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