So after my get-off a few months ago my 2008 GS got a small oil leak from the engine. I tried tightening all the bolts around the engine and found that some were pretty loose. However, I made the mistake of tightening them without a torque wrench and ended up applying too much torque. One bolt completely snapped off and a couple other bolts made loud snapping sounds as I tightened them (I don't know if they cracked or if it was the threads slipping that made that noise). I know, not the way you're supposed to do it, but I had absolutely zero wrench-work experience at the time and just didn't know what I was doing. :dunno_white: There are no cracks or anything in the engine case, so I think it's just the broken bolt or bolts causing the leak. I've tried to see where the leaking oil is coming from, and it's definitely coming from that part of the engine, right around where the broken bolt is--it's wet with oil around there.
Tightening the bolts mostly stopped the leak, but now that I'm riding more on freeways I've noticed that when I do longer high-speed rides it will leak a few drops of oil for a few minutes after parking the bike. It's a very small amount that leaks, I've only needed to add a couple ounces of oil after 2 months of daily riding, probably not much more than regular burn-off would have caused. Still, I'd like to fix this as I don't want to be dripping oil all over my apt. building's parking lot. I just wanted to get some advice on how to get the snapped bolt out of the engine. Here's a pic--the snapped bolt is towards the lower left corner:
(http://i1118.photobucket.com/albums/k601/ManyRPMs/IMG_0407.jpg)
You can see where the round plate got scratched up in the crash. You can also see the missing bolt--it's broken off inside the case, about 2-3mm inside the surface. I'm planning on using one of those broken bolt extractors with a power drill. Any particular bolt extractors members would recommend for these bolts? Also, what size bolt should I buy to replace it? I'm hoping none of the threads on the case are damaged, but if so can I repair that myself? And finally, what torque do I want to apply to the bolts? Don't want to over-tighten again, but want to prevent further leaks.
Had the same problem because of the previous owner of my bike.
Those bolts screw into the engine, Not the cover.
So if its broken off only slightly into the "Cover", then take the cover off and use some needle nose on the end if its sticking out of the engine.
Drain the oil before taking the cover off!
I had 2 broken on mine and luckily at least 1 was sticking out.
The other one was flush with the engine and I used too small of a bit to drill it out and that too broke off flush with the top.
Ended up leaving it as is and just putting a safe amount of gasket sealant around it to make up for it.
I also replaced the gasket behind the cover too.
Hasnt been a problem at all since.
If its broken flush with the engine and HAS to be drilled out.
If you dont have experience using those, from personal experience ^^ I would ask someone who does.
OR avoid my mistake, DONT use a bit too small. (used what the gf's dad was using but he was using it because the cover was still on and couldnt tell which to use)
Also, if you need a couple of those nuts and have absolutely NO way of simply going to a store or salvage yard to get them and Have to wait on shipping from somewhere.
Then I got some extras from my ordeal that I can toss in an envelope and mail to ya for nothin.
Don't use gasket sealant on any of the case side covers.It will get into the passages and oil when it squeezes out during tightening and plug them.Pull the cover.There should be enough of the bolt sticking out to unscrew it.If not,seek professional help.The engine case is thin in that area and it won't take much to crack it or cause a leak.Clean the gasket surfaces extremely well.DO NOT USE SEALANT.The gasket will swell and seal as oil soaks into it.Do not stick any thing between the cover and engine case to pry it loose.It will damage the soft aluminum mating surface and cause a leak that can't be repaired.Be prepared for the starter drive gear and shaft to drop out.They just slide back in the case before the cover goes on.Be aware that the rotor magnet pulls strong on the stator.Here is a write up I did.You can use the pics for reference and to know what goes where. http://gstwins.com/gsboard/index.php?topic=56037.0
My apologies then for some bad advice on the sealer.
Tho I should be safe as thinking back I think I thought not to put too much or any close to the inside because for multiple reasons.
I only put some (a thin application) on the "outer edge" around the broken bolt I couldnt get out.
Thanks for the advice. Since it doesn't seem like an urgent issue and it involves removing the oil, I think I'll wait until my next oil change to deal with this. That should be a month or 2. Tombsones, thanks so much for offering to send my a couple bolts if I need them. I'll see if I can buy some, but if not I'll definitely take you up on that and owe you a beer the next time I pass through your town :cheers:
Speaking of the bolts, I'm still wondering what size I need for replacement? Are they a standard size I can get at a hardware store, or should I go to a shop or dealer?
Thanks for the write-up Ben, that'll be a big help when I take off the side cover. I'm also wondering, should I buy a new gasket or stick with the one I have. I'm thinking the gasket should be fine, since it's a 2008 bike and the problem is with the bolts. I'll probably not buy one ahead of time.
Also, I was way off about how far in the bolt snapped off. I stuck a screwdriver in and measured how far it went, and it was almost an entire inch (21mm to be exact). So I'm guessing that might put it inside the engine and make it harder to remove. I'd like to try doing it myself, but I may have to finally bite the bullet and take my bike to a shop--don't want to risk messing up the engine.
Finger tight + 1/4 turn. Not too tight, just tight enought to not leak oil. Bring one of your good bolts to the hardware store and try to match up the threads and length, or spend a tiny bit more and order one from the motor cycle dealership.
Quote from: paalak on June 08, 2011, 12:37:20 PM
Thanks for the advice. Since it doesn't seem like an urgent issue and it involves removing the oil, I think I'll wait until my next oil change to deal with this. That should be a month or 2. Tombsones, thanks so much for offering to send my a couple bolts if I need them. I'll see if I can buy some, but if not I'll definitely take you up on that and owe you a beer the next time I pass through your town :cheers:
Speaking of the bolts, I'm still wondering what size I need for replacement? Are they a standard size I can get at a hardware store, or should I go to a shop or dealer?
Thanks for the write-up Ben, that'll be a big help when I take off the side cover. I'm also wondering, should I buy a new gasket or stick with the one I have. I'm thinking the gasket should be fine, since it's a 2008 bike and the problem is with the bolts. I'll probably not buy one ahead of time.
Also, I was way off about how far in the bolt snapped off. I stuck a screwdriver in and measured how far it went, and it was almost an entire inch (21mm to be exact). So I'm guessing that might put it inside the engine and make it harder to remove. I'd like to try doing it myself, but I may have to finally bite the bullet and take my bike to a shop--don't want to risk messing up the engine.
Replacing the gasket is a must when the side covers are removed.They almost always tear.The torque on the cover bolts is 18 INCH POUNDS of torque,not to be confused with FOOT POUNDS of torque.I also put a very small,almost insignificant, drop of medium thread locker(blue loctite) on each bolt.
and getting the old gasket out (for me anyways) was a Huge pain in the butt.
had to go very slowly and easily scrape (not to damage the metal) certain parts of it out.
if you happen to go to a hardware shop to get replacements next oil change, I would still send you a few to replace those just to be safe.
because (personally speaking) I wouldnt want anything but stock on major stock parts like that.
like the header bolts I bought today from Lowes to replace the 2 that fell out (got 4 to just do em all)
I still plan in a few mins to order the OEM ones and replace them when they arrive just to be safe.
but thats just me being better safe then sorry for the lack in such detailed mechanical knowledge.
actually ya know what, screw it.
your waiting for the next oil change to monkey with it.
Just give me your mailing addy and i'll mail 4 out to ya.
Will get there in plenty of time before the oil change comes up and you wont have to run around anywhere lookin.
(I did enough of that today! UGH)
as to why I have extras.
bought an extra cover from the salvage yard (came with All the bolts) after I bought the bike and planned to switch covers.
But after taking mine off, it was perfectly fine to put back on.
Only had to use 1 or 2 bolts from all the extras.
Tombstones, I sent you a PM. Thanks so much, it'll give me peace of mind knowing I have stock bolts in the engine when I'm doing 80 on the freeway.
Where can I buy the gasket? I looked around online but nothing so far.
Quote from: paalak on June 08, 2011, 08:21:34 PM
Tombstones, I sent you a PM. Thanks so much, it'll give me peace of mind knowing I have stock bolts in the engine when I'm doing 80 on the freeway.
Where can I buy the gasket? I looked around online but nothing so far.
www.bikebandit.com you need part 15 on the case cover diagram, gasket,magneto Suzuki part number 7208065-001 or bike bandit number 1038555 .
Thanks, just ordered the gasket from bikebandit. One more question: considering that the screw broke off 21mm below the case surface, what are the odds that it will be outside the engine when I take the case off, and removable with vice grips? If it's sure to be inside the engine, I figure I might as well just take it to a shop and save myself the trouble of removing the side cover. Anyway, I'll have the gasket and (thanks to tombstones) replacement bolts soon.
Quote from: paalak on June 09, 2011, 06:15:15 PM
Thanks, just ordered the gasket from bikebandit. One more question: considering that the screw broke off 21mm below the case surface, what are the odds that it will be outside the engine when I take the case off, and removable with vice grips? If it's sure to be inside the engine, I figure I might as well just take it to a shop and save myself the trouble of removing the side cover. Anyway, I'll have the gasket and (thanks to tombstones) replacement bolts soon.
21mm that is probably down in the case.I would let a shop remove it.The aluminum threads will strip easy if the bolt is center punched to hard so it can be drilled for an easy out.