Decided to spend the bank holiday monday here cleaning up my chain system as black sticky goop was getting on the chain from somewhere. The culprit was the roof of the chain guard.
However decided to take the sprocket cover off and thoroughly clean that too.
After cleaning it up with kerosene and a toothbrush for ages I went re-attach it. This is where the trouble started.
The Haynes manual said 20-24 newton meters of torque for the "8mm bolts on the crankcase". I set my torque wrench to 20 and started putting them home.
While cranking them, it seemed to me they were quite tight and I hadn't hit the spec so I turned the torque down to 16 newton meters.
Got four of the bolts in at that spec but the fifth one snapped off. Here is the pic when I took off the cover again:
(http://i.imgur.com/GTv6Ds8.jpg)
I have a European edition of the Hanyes manual but think the torque settings might wrong for some of them, can one of you guys tell me what you think the torque setting for these bolts should be? (Either in foot pounds or newton meters).
Should be able to get it out but I need to get a new bolt.
Is possible to find one or is it a non standard bolt?
I found this complete Allen Bolt set (http://www.ebay.co.uk/itm/260626652375) on ebay but I will need to get some allen bits for my torque wrench to use them. I would prefer to maybe just get one normal bolt. Seems to be a couple of sprocket covers sold with the bolts on ebay so I could get one of those too if I have to.
It's one of the smallest ones which I am missing:
(http://i.imgur.com/URdkmmg.jpg)
The trouble continues though..... :mad:
Seems I also snapped the bolt at the end of the clutch cable. Didn't think I tightened the lock nut too tightly but I guess I must have. Is there a torque setting for this nut?
(http://i.imgur.com/wv99ius.jpg)
So I'm going to buy a new cable too. Problem is, can't figure out which. Doesn't seem to be a Suzuki one on ebay so can anyone recommend any of these brands (http://www.ebay.co.uk/sch/i.html?_from=R40%7CR40&_sacat=0&_nkw=gs500+clutch+cable&rt=nc&LH_PrefLoc=3).
This Geiwiz cable (http://www.ebay.co.uk/itm/291112106923) looks about the priciest so maybe it's a superior one?
What do you think?
Thanks guys.
I have the 2000 model GS500 EY if that makes a difference
I made the same mistake, those are not the crank case bolts, they are cover bolts, the crank case bolts are hard steel and a few sizes larger, these bolts are not mentioned in the manual. They are supposed to be 5 to 7 nm. There is a rule of thumb that relates bolt size to torque, but I always forget it. The good trick for not over torqueing is to use the standard size spanner for that bolt, they are specially designed to give the correct feedback and to prevent stripping, with a long torque wrench handle it is easy to over tighten.
I never found ebay good for bike parts, I buy them from the web dealers like Ron Ayers. Good prices and original quality. No risk.
yeah 5-7 makes sense. Wish they mentioned this in the book. You think it is the same for the stator cover too? What are the crank case bolts then?
Not much choice in this neck of the woods other than ebay so it might have to do.
A quick look at a parts fiche shows those bolts holding the sprocket cover to be 6 mm dia and the short ones are 6x40 mm. Go to a good hardware store store and buy a bolt that size and a small flat washer or go to a dealer and order an oem one for a couple bucks. Parts fiche page:
http://www.shspowersports.com/fiche_section_detail.asp?section=92783&category=Motorcycles&make=SUZUKI&year=1997&fveh=2104
If you must tortque it go to the wiki torque listings and for bolts not listed use the general torque chart at the bottom and it will show 4-7 N-m for a 6 mm conventional bolt.
http://wiki.gstwins.com/index.php?n=Main.TorqueSettings
I rarely torque anything, been wrenching for 65 years.
Check the stator cover and crankcase bolt torque the same way.
Forgot, I've bought control cables from Ron Ayers and Motioi Pro online.
Those little bolts.. reckon 'nip them up' is about the right torque!
So right Janx, kids just need to learn about 'nipping-up 'and 'tweaking' nuts and bolts. You can FEEL when it's tweaked up right eh? No muscle strain, just nice and firm. So simple when you know how, but more difficult for beginners.
The REAL point with this is that this cover is not sealed therefore doesn't need a specific critical torque, all it's got to do is not come loose, so no need to overtighten and risking stripping threads.
(If it starts to come loose you'll no doubt hear it rattling away before it comes off!) Crankcase bolts are quite different, they have to contain oil pressure and need to be correct consistent torques to avoid distorting casings.
Thanks guys, bought the geiwiz cable of amazon as it was a bit cheaper. Got the complete allen set too as it will probably be useful to have some other spares.
Gonna be off the vroom-vroom for the rest of the week at least, I guess.
Need to learn how to lube a cable now.
Seeing as I have to wait for some parts, I'm going to give the sprocket cover a good clean. I was wondering though, you know this arm with the spring on it:
(http://i.imgur.com/IQaRKWo.jpg)
Is it east enough to take those philips head screws out and take the arm and spring off. Will anything pop out and there any hassle getting it back together?
That comes off easily as an assembly, no problem.
Thanks though I wouldn't say easily :D
I'm gonna need an impact driver for one of those screws and one at the back.
No! .. not unless last ditch resort with pirates chasing you! .. ;)
Better to use a exact fit screwdriver and some vice grips on the handle of screwdriver! ..
Screwdriver in screw head, firm pressure on butt of screwdriver to help keep it seated, steady rotational pressure with your vicegrips which increase your leverage... or a socket set with correct size bit/insert !!
Don't go Conan the Barbarian on the pressure!, just firm and steady!
Others may recommend the impact driver but I think that little screw and the metal it's screwed into would potentially suffer from impact strikes!
Remember they are not Phillips screw but JIS screw s, the drivers are different and you will be amazed how easily the screw come out with right driver. Of you damage them with a Phillips type driver best to just replace with Phillips screws from a good hardware store. Or get some JIS drivers, but they are expensive and harder to get.