SuzukiSavage.com - thank goodness I decided to helicoil

TallElf

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SuzukiSavage.com
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mistake by the lake
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thank goodness I decided to helicoil
02/12/17 at 06:45:35

Well, It all began last year when I bought this fine machine. With 6000mi on it. I fell in love with all 652 cc. Then I had an oil leak that was the headplug. Seemed easy to work on. Then I swapped out to a dyna pipe and a new jet in the carb. Seemed to quell the burping to a reasonable level. Then I noticed that I had a leak on the 130mm bolt so I tried to re tourqe them and pulled a small shard of metal out. Thought the PO might have coiled it himself but there was no magnetic force strong enough to be exerted on those threads. Drilled and tapped and gently inserted my first helicoil.

In disassembly at 10309 mi I found my cam chain tensioner about 6 clicks from imanent danger so I will be sending it off for reworking by a well known gentleman on the site. Searching the interwebs i have found several gaskets ranging from 21 to 39. Has anyone had success on the lower priced ones from fleabay or should I follow my conscious and go for the one from bike bandit? Also should I get a new head plug and a new cam plug? Or would the head plug i just replaced last year be good?

Is there anything else I should look into... Besides a piston kit as im not ready for that yet. I wanna ride as soon as the weather breaks with my brother.

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2001 glacier blue stock air 150 main stock pilot 2007 dyna exhaust.

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buster6315 Senior Member Offline SuzukiSavage.com Rocks! Posts: 353	Re: thank goodness I decided to helicoil Reply #1 - 02/12/17 at 07:04:15 I am confused to the terms 'head plug' & 'cam plug'
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TallElf YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 32 mistake by the lake Gender:	Re: thank goodness I decided to helicoil Reply #2 - 02/12/17 at 07:07:47 Head plug... Plug that goes into vertical hole to cover the head bolt and stop blowing oil on exhaust. Cam plug and i may ahve misnamed it. Black plug horizontally at top of head that covers the end of the cam shaft. I have seen black rubber ones like i have and metallic ones as well.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18101 Camp Springs, Kentucky Gender:	Re: thank goodness I decided to helicoil Reply #3 - 02/12/17 at 07:23:12 Definitely get a head plug made by Verslagen......or you will be doing it again someday. I re-use the cam plug if the rubber is not hardened, and depending on what year your bike is, they are sold in black or silver.
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TallElf YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 32 mistake by the lake Gender:	Re: thank goodness I decided to helicoil Reply #4 - 02/12/17 at 07:25:43 Anyone know what years were silver? I like the monochromatic look.
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justin_o_guy2

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East Texas, 1/2 dallas/la.

Re: thank goodness I decided to helicoil
Reply #5 - 02/12/17 at 12:48:02

I Got my clutch cover gasket from an independent shop. They have a machine that has a roll of gasket paper and a Printer that has a blade and hole punches. It doesn't have the OEM sticky stuff strategically located, but it was $14.00, several years ago.
They stocked filters and orings, cheaper than Suzuki shop prices.
They stuck a CD in, picked the gasket, hit a button and it started humming, buzzing and clacking , paper started poking out, and in just a coupla minutes, Presto, a gasket.. Neat machine.

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The people never give up their liberties but under some delusion.- Edmund Burke.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18101 Camp Springs, Kentucky Gender:	Re: thank goodness I decided to helicoil Reply #6 - 02/12/17 at 13:58:40 TallElf wrote on 02/12/17 at 07:25:43: Anyone know what years were silver? I like the monochromatic look. I would think the 86 model was silver....not sure how long after that it continued.
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Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1452	Re: thank goodness I decided to helicoil Reply #7 - 02/12/17 at 16:45:45 Maybe time for a new cam chain, or at least a cam timing adjustment?
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TallElf YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 32 mistake by the lake Gender:	Re: thank goodness I decided to helicoil Reply #8 - 02/12/17 at 17:40:35 I figured id get an adjusted cam chain tensionerwith the 2nd hole. And when I put it back together make sure timing is right. I've got some reading to do in that area.. And following closely with mr. Clymer
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: thank goodness I decided to helicoil Reply #9 - 02/14/17 at 08:31:48 What he's talking about isn't in the book.
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springman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2217 Spring, Texas Gender:	Re: thank goodness I decided to helicoil Reply #10 - 02/14/17 at 12:10:42 I have bought and used 2 clutch cover gaskets from ebay and both have worked just fine as long as you torque the bolts correctly.
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justin_o_guy2

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East Texas, 1/2 dallas/la.

Re: thank goodness I decided to helicoil
Reply #11 - 02/14/17 at 16:32:34

It's a lot easier to snug one up than repair a stripped out hole. A 1/4" ratchet and one hand just closing the fingers with the thumb on the ratchet head, proper criss cross pattern till it's snugging up good, then you can work around and get that
It's tight
Feeling.
An end wrench will get behind the pipe if it isn't perfect.

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The people never give up their liberties but under some delusion.- Edmund Burke.

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piedmontbuckeye

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Easley, SC
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Re: thank goodness I decided to helicoil
Reply #12 - 02/17/17 at 13:19:37

justin_o_guy2 wrote on 02/14/17 at 16:32:34:

It's a lot easier to snug one up than repair a stripped out hole. A 1/4" ratchet and one hand just closing the fingers with the thumb on the ratchet head, proper criss cross pattern till it's snugging up good, then you can work around and get that
It's tight
Feeling.
An end wrench will get behind the pipe if it isn't perfect.

Great advice. I do this a lot of times, and just go back after a few weeks and re-check that everything is OK!

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"The difference between death and taxes is that death doesn't change every time congress meets." - Will Rogers

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