SuzukiSavage.com - Permanent Removal of Head Covers

Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Permanent Removal of Head Covers Reply #15 - 02/01/15 at 23:01:47 Dave, I think I understand the procedure for "Permanently Removing The Chrome Head Cover Caps". And your explanation of the spacer for the front bolt on the shifter side tells me what I have to do. With the other 3 bolts do I just screw them back into the head, or head cover? Kenny G
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18098 Camp Springs, Kentucky Gender:	Re: Permanent Removal of Head Covers Reply #16 - 02/02/15 at 03:41:11 stinger wrote on 12/15/14 at 07:22:20: Begins to unwrap the chrome head cover caps I was mailing to you all as Xmas gifts.... We are mailing all the unused covers to Serowbot. He is going to use them to make a chrome Armadillo mailbox.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18098 Camp Springs, Kentucky Gender:	Re: Permanent Removal of Head Covers Reply #17 - 02/02/15 at 03:42:33 Kenny G wrote on 02/01/15 at 23:01:47: Dave, With the other 3 bolts do I just screw them back into the head, or head cover? Kenny G Just put the other 3 bolts in the box with the head cover caps, and mail it to Serowbot. You don't need them as their only function is to hold the head cover caps in place.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Permanent Removal of Head Covers Reply #18 - 02/02/15 at 05:49:41 And,as for the long, upside down bolt, I don't see why running a nut down and cutting it off wouldn't work better..
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Re: Permanent Removal of Head Covers
Reply #19 - 02/02/15 at 05:51:50

justin_o_guy2 wrote on 02/02/15 at 05:49:41:

And,as for the long, upside down bolt, I don't see why running a nut down and cutting it off wouldn't work better..

The long upside bolt doesn't have threads that run all the way down...you have to install a sleeve that covers up the un-threaded portion so the nut can be tightened down.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Permanent Removal of Head Covers Reply #20 - 02/02/15 at 06:12:11 WELL Dave,, that right there is reasonable... Me, I'd wanna get the head off of the bolt, pull it, drop a shorter bolt in and get a nut on it, If there is room with the chrome gizmo gone.. but the stack looks tacky to me. You bring me that bike for a year and I would fix that for you... I would. Really.
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Re: Permanent Removal of Head Covers
Reply #21 - 02/02/15 at 06:21:38

justin_o_guy2 wrote on 02/02/15 at 06:12:11:

Me, I'd wanna get the head off of the bolt, pull it, drop a shorter bolt in and get a nut on it, If there is room with the chrome gizmo gone.. but the stack looks tacky to me.
You bring me that bike for a year and I would fix that for you... I would. Really.

(That photo I took from the Rubber Plug repair thread in the Tech Section....it is not my bike).

When I rebuilt mine and had the cylinder head off....I put in a threaded rod that was cut to the long length with a nut on the bottom that was "thread lockered" on real good! That way I could remove the long stud and put in a shorter one later on when I removed the head covers.......the engine went back in with the stock head covers on as the Cafe' conversion was a year later. My gas tank sits so low that you really can't see the long stud unless you get down to look it it.....but I will fix it this winter so it doesn't bother you.

I betcha you could fix this is less than a year.....if you stopped riding it for a few minutes! Grin

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Permanent Removal of Head Covers Reply #22 - 02/02/15 at 06:31:30 You're right, I'm busted,, I would fix it the day you come to get it. Please deliver it with fresh rubber on it...
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Permanent Removal of Head Covers Reply #23 - 02/02/15 at 06:46:49 Dave, One final question and then I will leave you guys go back to arranging transportation for your bike to Justin 'O: Is their any special torque requirement for tightening the remaining long bolt after removing the "Chrome Head Cover Caps"? Kenny G
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Re: Permanent Removal of Head Covers
Reply #24 - 02/02/15 at 06:54:05

Kenny G wrote on 02/02/15 at 06:46:49:

Is their any special torque requirement for tightening the remaining long bolt after removing the "Chrome Head Cover Caps"?

Kenny G

Just torque it to the same tension as the other 6mm head cover bolts....5.9 - 8.8 ft. lbs. This is really just "snug" with a small 6mm hex end wrench. Don't crank down on these bolts as they are small and easily stripped.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Permanent Removal of Head Covers Reply #25 - 02/02/15 at 06:58:27 Feel of it,don't strip it, if it leaks, give it a little bit more. A healthy bolt and nut have a feel when they hit Max clamping force, PROVIDED you are holding the tools in a manner that Allows you to Feel it.
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Permanent Removal of Head Covers Reply #26 - 02/02/15 at 07:10:20 Dave & Justin, Thank You! I never broke a bolt or stud or stripped the threads on a motorcycle until I bought my first torque wrench. LOL Unless it is inside the engine, or transmission, I don't use a torque wrench, I just make fasteners "Good N' Tight. Or as Justin says I tighten by "Feel". Kenny G
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Re: Permanent Removal of Head Covers
Reply #27 - 02/02/15 at 07:22:13

When I got my bike...it was 3 years old but well taken care of.

When I changed the oil.....I had to use both hands on the wrench and wedge my foot against the frame to get the oil drain plug loose! It was waaaay too tight....and unfortunately that is not all that uncommon. A lot of folks tighten things more then they should.

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Kenny G

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Re: Permanent Removal of Head Covers
Reply #28 - 02/02/15 at 07:38:20

After I re-assemble anything on a motorcycle I go for a ride and come back to the house and go over all of the fasteners to check for "Tightness" and snug everything up again. I will check the fasteners again after the next ride and if I have to tighten anything again I will use Blue Loctite. If after the next ride I find anything that needs "Tightened" I will safety wire it.

The "Big Singles" that I rode back in the "Olden Times" vibrated everything loose, including spot welds. If you wanted to ride a "Big Single" you would become acquainted with "Safety Wire".

Kenny G

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Re: Permanent Removal of Head Covers
Reply #29 - 02/02/15 at 11:31:32

When I removed my head cover caps, I replaced the vacated bolts (except the left front) and installed cleaner, better looking bolts in their places with lock washers. As for the left front, I have a hack saw blade holder and just sawed it off. A complete hack saw won't fit and a Dremel cutoff wheel is not long enough. I held the protruding top of the bolt with vise grips and sawed at the bottom of the bolt. When cut through, the bolt head slides out easily and the severed bolt just pulls straight out. Blow out the chips and go ride!

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