broken oil cover stud

[FatBastard]

okay, so I was just having my nice day today changing my oil, planing on going for a ride after and bam, 70% done changing the oil and one of the studs that the bolts snug up to that hold the oil fillter cover broke on me, I didn't put that much pressure on it and it went, my theory is to blame it on my last mechanic because all the bolts felt like they had been impact wrenched on (took 90 ft pounds of torque to undo the oil pan plug), but thats not important, what I do need to know is how to replace it. There is still alot of stud showing(thankfully it didn't break off at the crankcase) at least half an inch. What I need to know is what is the best way to get it out. It looks like there is enough room for a vice grip but is there lock tight on the other side or is that just a very bad plan altogether? Will post pictures tomarrow, thanks

[BeerGarage]

vice grips, pray to god, turn, curse god.

drill, ez out, pray to god, turn, curse god.

drill, helicoil, pray to god, turn, curse god.

broken bolts lead to burning in hell, basically, no way around it.

[joshr08]

everything youll ever need to know about oil cover stud can be found in this link click and check it out.

http://gstwins.com/gsboard/index.php?action=search

[FatBastard]

2 things 1) the search engine needs a better SEO (also known as search engine optimization) cause I didn't find much info till the second try 2) This seems to be pretty damn common, we need to put this on the wiki so people can not be superfreaked like I was and also so it's just there. Also, why the hell did suzuki make these damn bolts so easy to break? Lastly a nice big to the mechanic who used a impact wrench by all appearance to tighten my bolts because that probably didn't help. Wish me luck all that mr vice grip is in a good mood when I ask for his help.

[sledge]

why the hell did suzuki make these damn bolts so easy to break?

They didnt make them easy to break. I have never broke one and the same applies to many other owners. If you follow Suzukis instructions on removal/refitting the cover and torquing up the fastenings to the letter you wont shear them. Ignore these instructions you are out on your own with no one else to blame......bit unfair to blame Suzuki for the failings of an individual ignorant of the facts and who thinks they know better.

If you claim the fastenings have been overtightened in the past and are now stressed I suggest you repace all 3 studs together, otherwise you will have the same problem next time you carry out the procedure.

[the mole]

I suggest that before you use the vise grips, you give the end of the broken stud a sharp tap with a hammer.

[FatBastard]

hooray! vice grips worked! Now the only question I have is is that the kind of thing suzuki would have in stock? Also would they have the star clip on the bottom of the fairings in stock?

[sledge]

Studs, part#465559-001. $1.17 each. Suzuki will have them in, as to if your local dealer has them in......its another question altogether.

[BeerGarage]

Studs are a PITA.  The local hardware store has metric bolts in for $0.20 each.  Just my $0.02.

[sledge]

Studs are used for a reason. Hi-tensile bolts in soft-alloy threads are not a good idea.

[FatBastard]

okay, got the old one out and am getting the new stud today, how do I put the new one in? Locktight it? Little help here

[jeremy_nash]

if you put locktite on it, use the blue, it is meant to be removed, the red isnt