SuzukiSavage.com - Mistakenly removed a bolt from the engine head

bwt72 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Mistakenly removed a bolt from the engine head 06/17/20 at 10:11:44 now I’m having trouble putting it back because it’s a rather long bolt and there seems to be something inside the hole that the bolt fits into - however, it has moved down and the holes are no longer aligned
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bwt72 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Mistakenly removed a bolt from the engine head Reply #1 - 06/17/20 at 10:23:51 I’m trying to get the bolt back into the engine. Any help would be greatly appreciated. Thank you!
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2633 Amongst the Twisty Roads	Re: Mistakenly removed a bolt from the engine head Reply #2 - 06/17/20 at 10:46:47 That bolt is rather important. It secures the cam chain tensioner to the cylinder head. DO NOT attempt to start the engine. Why did you remove it?
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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: Mistakenly removed a bolt from the engine head Reply #3 - 06/17/20 at 11:13:31 You're gonna have to remove the clutch cover to get that back in. measure the cam chain tensioner while you're at it.
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norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: Mistakenly removed a bolt from the engine head Reply #4 - 06/17/20 at 12:44:59 Right on Versy. It could be worse If he had tried to start it.
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5106 Manteca , CA Gender:	Re: Mistakenly removed a bolt from the engine head Reply #5 - 06/17/20 at 13:03:37 "Here's you sign"
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5106 Manteca , CA Gender:	Re: Mistakenly removed a bolt from the engine head Reply #6 - 06/17/20 at 13:06:53 Spare yourself some serious abuse Invest in a shop manual
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5106 Manteca , CA Gender:	Re: Mistakenly removed a bolt from the engine head Reply #7 - 06/17/20 at 13:12:07 Please tell us that you DONT disarm bombs for a living !
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Gary_in_NJ

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Re: Mistakenly removed a bolt from the engine head
Reply #8 - 06/17/20 at 13:22:41

BWT,

It's not hard to reinstall the cam chain...it's just rather involved. You have to remove the forward controls, the exhaust and the right side case cover. From there you have to loosen the ACCT (as verslagen mentioned, measure the extended portion and report back). Once the tension is off the chain I believe you will be able to reinstall that bolt from there.

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bwt72

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Re: Mistakenly removed a bolt from the engine head
Reply #9 - 06/17/20 at 13:59:22

Thanks Gary! It actually wasn’t me who removed it but my fiancé in an effort to replace the spark plug of all things Cool

Thinks she’s mechanically inclined tho I should of been there... and she was going to leave it there for all time cluttering up my garage. I knew that me giving her that bike was going to come back to bite me. Thank you!

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justin_o_guy2

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What happened?

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Re: Mistakenly removed a bolt from the engine head
Reply #10 - 06/17/20 at 14:30:01

BEFORE ya start removing bolts from the side cover, grab cardboard and draw an outline, jab slots where every bolt goes,,and stick each bolt in its slot as they come out, or youll create a puzzle..

Be Gentle tightening them,, 1/4"ratchet, thumb on the head, gently closing fingers to turn the bolt,, FEEL of it, dont try to tighten Any of them,, just snug them, going across and get them snug,, hten make another pass and another, and just because
Thats the next one And youre still tightening,, if you find one that requires more torqu to turn than the last one,, skip it,, just keep working around the cover till all of them feel tight,, They arent head bolts,,,, Its a LOT quicker taking the time to Not break anything than hurrying and bustin stuff or stripping threads.
Its easier to fix a leak than a busted anything,,

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bwt72 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Mistakenly removed a bolt from the engine head Reply #11 - 06/17/20 at 15:44:27 Will do, thank you!
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bwt72

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Re: Mistakenly removed a bolt from the engine head
Reply #12 - 06/25/20 at 14:40:05

Finally got around to working on the bike today and the advice made it easy get the bolt back into the engine - Thank you! Although, I didn’t have the correct tool for putting the clip in the photo back on to the cam tensioner.. and didn’t want to break it by forcing the clip. Can you tell me what it is called?

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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2633 Amongst the Twisty Roads	Re: Mistakenly removed a bolt from the engine head Reply #13 - 06/25/20 at 14:59:11 It’s a circlip. There are special pliers to insert and remove these.
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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: Mistakenly removed a bolt from the engine head Reply #14 - 06/25/20 at 15:48:25 Harbor freight has them, but these are extra small and don't fit w/out forcing them on.
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