SuzukiSavage.com - Replaced rubber plug, leaking around oval cover

joe H

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Replaced rubber plug, leaking around oval cover
05/31/22 at 05:16:56

Replaced the rubber plug tthis weekend, that went well, re sealed the top end, put it all back together, now I have a leak around the top oval cover that's closest to the battery, the one in the front is fine. Took it back off, and slapped some instant gasket on it, just to see, same thing. O ring looked fine, but I have ordered a replacement for that, thinking that will fix it, anyone else have any thoughts?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28845 L.A. California Gender:	Re: Replaced rubber plug, leaking around oval cove Reply #1 - 05/31/22 at 06:49:00 there are a couple bolts on the cover that take sealing washers... maybe you missed one?
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joe H YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 9	Re: Replaced rubber plug, leaking around oval cove Reply #2 - 05/31/22 at 13:47:12 Hadn't thought of that, maybe I need to look right after it runs to make sure it's leaking from there. Joe
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Replaced rubber plug, leaking around oval cove Reply #3 - 05/31/22 at 14:20:58 It's too late for this job In the future When you take anything apart Get a piece of cardboard, draw the outline of the part of the engine, stick a slot in the cardboard and put the scfews in the slots. That way you will have the Right screw in the right place.
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joe H

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Re: Replaced rubber plug, leaking around oval cove
Reply #4 - 06/01/22 at 11:21:14

justin_o_guy2 wrote on 05/31/22 at 14:20:58:

It's too late for this job
In the future
When you take anything apart
Get a piece of cardboard, draw the outline of the part of the engine, stick a slot in the cardboard and put the scfews in the slots. That way you will have the Right screw in the right place.

I actually did that, so it might just be that I didn't torque one enough, I'm always paranoid about stripping the bolts.

Joe

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justin_o_guy2

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Re: Replaced rubber plug, leaking around oval cove
Reply #5 - 06/01/22 at 13:24:05

I'm always paranoid about stripping the bolts.

That is Not paranoid

Use your1/4" ratchet and use your Fingers to feel the way to Tight. No way would I use torque wrenches. You can Feel a bolt come to the spot where it is Clamping the parts together.
I don't Just go through the torque pattern. I do it more times, and just carefully increase the torque as I go through each pass.
It's okay to get bolts and destroy them in a vise .
Learn what it Feels like when a threaded connection is failing.
It will save you tons of crap.

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joe H

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Re: Replaced rubber plug, leaking around oval cove
Reply #6 - 06/04/22 at 19:23:51

justin_o_guy2 wrote on 06/01/22 at 13:24:05:

I'm always paranoid about stripping the bolts.

That is Not paranoid

Use your1/4" ratchet and use your Fingers to feel the way to Tight. No way would I use torque wrenches. You can Feel a bolt come to the spot where it is Clamping the parts together.
I don't Just go through the torque pattern. I do it more times, and just carefully increase the torque as I go through each pass.
It's okay to get bolts and destroy them in a vise .
Learn what it Feels like when a threaded connection is failing.
It will save you tons of crap.

Update- I missed a darn bolt in the engine top, it was just finger tight, snugged it up, and he's all good now. You guys rock, btw, and while I have an 85 vmax, I gotta say I loved riding this little bike testing it out, it's just so much fun!

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