SuzukiSavage.com - Broken clutch cover bolts

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Broken clutch cover bolts
03/16/14 at 08:29:12

Recently I took my clutch case cover off to check my tensioner. When I put it back on, I over torqued a couple of the bolts and even broke one. I should have bought a torque wrench. Now I have the wrench, but I can't find replacement bolts anywhere. The hardware stores around me (St. Louis) don't sell a lot of chromed bolts, and Bike Bandit has them on their diagram but doesn't have them listed with a price. I am talking about number 5 and 6 on their diagram. Does anyone have any idea where I can buy or order these?

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S-P Serious Thumper Offline Back in the saddle again Posts: 816 Phoenix, AZ Gender:	Re: Broken clutch cover bolts Reply #1 - 03/16/14 at 08:37:39 BUY A TORQUE WRENCH, NOOBS!!! :'( Ebay sellers often have sets for about 15.00. I'd check there. Probably less than an individual OEM bolt.
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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: Broken clutch cover bolts Reply #2 - 03/16/14 at 08:48:15 ace hardware is supposed to have a large collection. or http://www.partsoutlaw.com/oempartfinder.htm?aribrand=SUZ&arian=Motorcycle#/S... $1.16 a bolt
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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Broken clutch cover bolts Reply #3 - 03/16/14 at 09:21:05 Boltdepot.com They have a pretty large selection of anything that I've ever needed. By the way, what size are those bolts?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Broken clutch cover bolts Reply #4 - 03/16/14 at 09:34:44 Torque wrench? Naah, 1/4" ratchet & No Closed Fist on it. Thumb on ratchet head & squeeze fingers in, FEELING the bolt as it snugs up. YOu can feel it when it stops. If it leaks, snug a bit more where you think you must, but bolts will tell you when its time to stop, once you learn how to listen,
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jimmysmooth YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 14	Re: Broken clutch cover bolts Reply #5 - 03/16/14 at 12:13:03 Thanks, I will check those websites out. I was pretty concerned about tightening too much, so I hand tightened them with a hex bit on a screwdriver. Then it oozed out at the seal. So I tried a little tighter with ratchet, but I went too far.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Broken clutch cover bolts Reply #6 - 03/16/14 at 14:24:56 Id rather have to snug several times than replace busted stuff.. Things dont always go so smooth, ehh Jim?
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S-P Serious Thumper Offline Back in the saddle again Posts: 816 Phoenix, AZ Gender:	Re: Broken clutch cover bolts Reply #7 - 03/16/14 at 17:43:45 justin_o_guy2 wrote on 03/16/14 at 09:34:44: FEELING the bolt as it snugs up. YOu can feel it when it stops....bolts will tell you when its time to stop, once you learn how to listen, JOG, the Force was weak in this one....
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old_rider

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Re: Broken clutch cover bolts
Reply #8 - 03/16/14 at 18:34:45

jimmysmooth wrote on 03/16/14 at 08:29:12:

Recently I took my clutch case cover off to check my tensioner. When I put it back on, I over torqued a couple of the bolts and even broke one. I should have bought a torque wrench. Now I have the wrench, but I can't find replacement bolts anywhere. The hardware stores around me (St. Louis) don't sell a lot of chromed bolts, and Bike Bandit has them on their diagram but doesn't have them listed with a price. I am talking about number 5 and 6 on their diagram. Does anyone have any idea where I can buy or order these?

Harbor Freight has cheap torque wrenches sometimes if you have a coupon or they are having sales
http://www.harborfreight.com/catalogsearch/result?q=Torque+wrench

I'll look around to see if I can find a place with a parts listing of the bolts

here is a bike parts site with breakdown, see if you can find the bolts and if it tells you the size

http://www.bikebandit.com/1997-suzuki-savage-650-ls650p/o/m147792#sch239634

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Re: Broken clutch cover bolts
Reply #9 - 03/16/14 at 20:38:30

Home Depot, Lowe's, Ace, etc. Any place that sells stainless steel metric allen bolts. You really don't want chromed mild steel fasteners rotting away on a visible section of the engine.

And forget about o.e.m. style paper gaskets, gray goop (high temp rtv) works better.

The only easily serviced, torque wrench required fasteners are the clutch basket and drive pulley ones. Everything else, finger tight, retension after a heat cycle or two. You may want a torque wrench for the head cover nuts, but, until you are forced to replace the cam chain, you don't really need one. Even the tensioner widget is just held on with a circlip...

I'm odd, my bike has leaked like an old Triumph Bonneville or pre-Magnum Dodge truck engine since day one. Haven't checked the valves in years, every time I checked them the gap was within spec.

You guys worry too much.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Broken clutch cover bolts Reply #10 - 03/17/14 at 10:05:48 I watched the soft point on the valve adjuster mush down & work harden, I watched the valves slowly stop needing fiddled with. At 20,000 I tightened them up, just because I want them set on the tite side.
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Michael L

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Re: Broken clutch cover bolts
Reply #11 - 03/17/14 at 10:18:05

Are you sure you didn't strip the threads in the alu casing...? I find it hard to believe you broke a steel bolt before stripping the thread.. Anyway, just as justinoguy explained, that's the only right way to go.. A 1/4 with a snug hand and you're done.. IF it would begin to leak, in which I doubt it will, you can just give them 10 degrees more...

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justin_o_guy2

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Re: Broken clutch cover bolts
Reply #12 - 03/17/14 at 11:36:25

Get 2 plates, put a bolt thru, put a nut & bolt in, use 1/4" ,, something small, use cheap, crappy bolts & feel of them. Strip a few, get close to stripping them, pull a nut & flip it & try to put it back on.. Youll know it was stressed if it wont go "upside down". The threads will be distorted.
Youll get the feel of a bolt that has hit its max clamping force. Yea, youll waste an hour or more & spend a coupla bucks on stuff to ruin, but in the long run, youll save hours of hassles & who knows how many dollars.

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Re: Broken clutch cover bolts
Reply #13 - 03/17/14 at 12:56:49

justin_o_guy2 wrote on 03/17/14 at 10:05:48:

I watched the soft point on the valve adjuster mush down & work harden,
I watched the valves slowly stop needing fiddled with. At 20,000 I tightened them up, just because I want them set on the tite side.

What is the benefit to a bit on the tight side (except maybe eliminating the tick). On my VW they recommended a little loose so they didn't burn.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Broken clutch cover bolts Reply #14 - 03/17/14 at 15:47:27 On the tight side of the specs,, not tighter than spec, ever. Hey, I paid for a cam that lifts & holds them open,, the least I can do is set them to open as far as I can, safely..
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