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Plug Cap leak repair question (Read 84 times)

DesertRat Serious Thumper Offline I love rat bikes! Posts: 1569 Arizona	Plug Cap leak repair question 09/24/15 at 06:52:44 found the write up in the Tech section and was wondering if this repair can be done without engine removal? also need clarification: does the engine have to be at TDC?
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youzguyz Serious Thumper Offline Posts: 2538 San Antonio, Texas Gender:	Re: Plug Cap leak repair question Reply #1 - 09/24/15 at 07:21:35 Yes and Yes
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Re: Plug Cap leak repair question
Reply #2 - 09/24/15 at 07:22:14

The engine can remain in the frame.

The engine should be at TDC so that the cam lobes are not pushing on the rocker arms. If you attempt to take off (or replace) the cylinder head cap while the cam is pushing a valve open.....it is applying a lot of pressure on the cylinder head cap and will make it impossible to remove or replace properly.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Plug Cap leak repair question Reply #3 - 09/24/15 at 08:36:03 I was pleasantly surprised the last time I removed the cover upon removing the last bolt (the center most one fortunately) that the cover slowly rose with the bolt. So while it may be good technique, not mandatory for removal. But you will need to set it to TDC for replacement.
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DesertRat Serious Thumper Offline I love rat bikes! Posts: 1569 Arizona	Re: Plug Cap leak repair question Reply #4 - 09/24/15 at 13:35:08 THANKS GUYS ... y'all rock!
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DesertRat Serious Thumper Offline I love rat bikes! Posts: 1569 Arizona	Re: Plug Cap leak repair question Reply #5 - 09/24/15 at 14:06:27 Ive read here that quite a few folks broke old ones during the torque process, should I buy all 13 bolts as new replacements instead of reusing the old ones?
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Re: Plug Cap leak repair question
Reply #6 - 09/24/15 at 14:54:55

DesertRat wrote on 09/24/15 at 14:06:27:

Ive read here that quite a few folks broke old ones during the torque process, should I buy all 13 bolts as new replacements instead of reusing the old ones?

Most times they don't break, sometimes you just need new threads, sometimes you need a longer bolt to reach new threads.
You certainly can circumvent the breakage and worn threads issue by doing this.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18098 Camp Springs, Kentucky Gender:	Re: Plug Cap leak repair question Reply #7 - 09/24/15 at 18:50:51 And don't over-tighten the bolts...they are small and thread into aluminum. They should only be made snug.....not tight. The proper torque is only 6-8 ft.lbs.....you can't use a 150 ft/lb torque wrench and get any kind of a click at those low settings.
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Re: Plug Cap leak repair question
Reply #8 - 09/24/15 at 20:14:31

Ya don't torque them. You start in the middle and work out, just snug, and as you repeat the process, and just use finger closing against a thumb on the head of the tool, be slow and careful.
The time it takes to repair a mistake is too much. At the end you'll be moving the bolt almost none.
It's okay if you make the pattern eight times, who cares? Try it in two,, probably not gonna be a good day..

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old_rider

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Re: Plug Cap leak repair question
Reply #9 - 09/24/15 at 21:36:54

Kinda like torqueing aircraft parts..... start by snugging... then in lower increments first (usually 5 inch/or if in foot lbs 2-3ft pounds)

Like JoG says... snug...again.....snug....again....little pressure....

I think I did mine about five times, with the fifth time of no movement..... mine doesn't leak at the head...LOL... I have a bad valve cover seal... (which I plan to fix this cold season).

If you don't feel safe with your hand judgement.... go to an auto parts store and rent one..... that has the proper torque values.....

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