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Cylinder Head Fastener Upgrades (Read 627 times)
DragBikeMike
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Honolulu
Re: Cylinder Head Fastener Upgrades
Reply #75 -
10/23/23 at 20:21:41
It's the same sealing washer used on the head cover bolts and the three clutch cover bolts. OEM part number is 09168-06023.
OCH, that McMaster & Carr gasket is solid rubber. You can't stress the fastener properly because the rubber will deflect. The OEM gasket is a neoprene insert surrounded by a metal ring. When you tighten the fastener the rubber deflects until the fastener contacts the metal ring. Then the fastening system is metal-to-metal and you can properly stretch the bolt.
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och
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Re: Cylinder Head Fastener Upgrades
Reply #76 -
10/24/23 at 08:14:13
Good to know. When I used longer bolts, I reused the stock sealing washers.
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TheSneeze
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Re: Cylinder Head Fastener Upgrades
Reply #77 -
10/24/23 at 10:46:40
Thanks, DBM!
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Every twenty minute job is a stripped thread away from being a three day ordeal.
'87 LS650h Savage Street Tracker (destroyed by fire)
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribut
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LPHRN
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Re: Cylinder Head Fastener Upgrades
Reply #78 -
Yesterday
at 18:39:54
These are slightly out of order, sorry.
Drag Bike Mike, thank you for all your research and pictures. I am here to tell you that repair you outlined for the right rear head cover bolt works perfectly!
I did pull the head with the engine in the frame, but honestly if I had to do it over, I wouldn’t. I think there are a number of ways to keep shavings out of the oil passages. Also, the hole in the head gasket is large enough I don’t think the drill could nick it and get steel shavings into the mix. And, if I ever buy another of these bikes I would probably drill out both of the right-side bolts during a head cover job just to save having to do it later.
The faucet-facing tool worked just fine after modifying it as you suggested. I used it a little differently since I am lazy. The spring maintains tension, the rags and duct tape keep shavings where they belong. Turn the jam nut on the bottom to tighten, and the cutter’s teeth are then going the right direction. If anyone out there wants to borrow it let me know.
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LPHRN
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Re: Cylinder Head Fastener Upgrades
Reply #79 -
Yesterday
at 18:40:43
I used ¼” bolts since I couldn’t find 6mm bolts that long. That precluded using the Suzuki sealing washers. I used this type, and I will tell you now, they will deform, crush, and look totally destroyed when torqued to 100 inch pounds. However, they don’t leak.
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LPHRN
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Re: Cylinder Head Fastener Upgrades
Reply #80 -
Yesterday
at 18:45:54
The finished product. The engine is so oil tight I can’t get over it. Much better than it has ever been over the last 4 years.
Thanks to everyone on the forum who contributed to this topic!
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