Ok, I had to split the case on my 95 GS to replace a broken rear cam chain tensioner.  Once the tensioner was replaced I started to put the cases back together.  All was going well until I was torqueing the bolts as described in the clymer manual and THREE (3) of the case bolts broke!!     Now the cases have to come apart again so I can extract the broken bolts!!  Should I have purchased new case bolts instead of using the old ones?? 

Quote from: cosmiccharlie on May 24, 2007, 07:29:34 PM
Should I have purchased new case bolts instead of using the old ones?? 

Apparently so.

Quote from: AlphaFire X5 on May 24, 2007, 07:33:36 PM
Apparently so.

Well shaZam!!  The manual didn't tell me that!  It told me to stick the old ones in a piece of cardboard in order so I would know where the went when I put the cases back together!     shaZam!!!

Quote from: cosmiccharlie on May 24, 2007, 07:39:43 PM
Well shaZam!!  The manual didn't tell me that!  It told me to stick the old ones in a piece of cardboard in order so I would know where the went when I put the cases back together!     shaZam!!!

Well yeah, but apparently you should have replaced them since they broke.

Quote from: AlphaFire X5 on May 24, 2007, 07:41:22 PM
Well yeah, but apparently you should have replaced them since they broke.

Ok wise guy, how would I have known they were going to break??  Question is should the case bolts be replaced any and every time the case is opened up?? 

Quote from: cosmiccharlie on May 24, 2007, 07:45:01 PM
Ok wise guy, how would I have known they were going to break??  Question is should the case bolts be replaced any and every time the case is opened up?? 

I have no idea. Personally, I wouldn't think they'd need to be replaced every time the case is opened.

Quote from: AlphaFire X5 on May 24, 2007, 07:49:52 PM



I have no idea. Personally, I wouldn't think they'd need to be replaced every time the case is opened.

I wouldn't either, but three of mine broke!!     The bike has 22k miles on it. 

Torque wrench? Used it?

Quote from: cosmiccharlie on May 24, 2007, 07:29:34 PM
All was going well until I was torqueing the bolts as described in the clymer manual

Umm....yes I was using a torque wrench.  I am not a freakin' idiot!!

That sucks man , the bolts are also different lengths if I remember

I am posting because I wanted to know if anyone who has experinece spliting a gs case has run into this problem.  If you have no experience or anything helpful to say DON'T POST!!  I followed the manual to a T and I use a torque wrench (duh!  )!!  

I guess I should have never posted here.  I will just order all new case bolts.  Thanks for nothing!  

Quote from: cosmiccharlie on May 24, 2007, 07:39:43 PM
It told me to stick the old ones in a piece of cardboard in ORDER so I would know where they went when I put the cases back together!

Yes they are different lengths, hence the reason I stuck them in a piece of cardboard in order so I would know where they went when I re-assembled the cases.  Again a step I read in the clymer manual. 

I've split my cases and didn't have any issues with those bolts so   

That sucks man, Alpha, try helping instead of riling him/her up.  Sometimes this shaZam! just happens, just be glad that it's only a few bolts instead of something catastrophic.

Quote from: Affschnozel on May 24, 2007, 08:53:19 PM
I've split my cases and didn't have any issues with those bolts so   

It's cool man.  I am just frustrated now. 

Quote from: cosmiccharlie on May 24, 2007, 08:48:24 PM
If you have no experience or anything helpful to say DON'T POST!!

If you don't want people to post, don't put things in a public forum. Sucks about your luck though.

Quote from: NiceGuysFinishLast on May 24, 2007, 09:09:03 PM

If you don't want people to post, don't put things in a public forum. Sucks about your luck though.

That's kinda ridiculous man,  the reason this board exists is to bring people together to discuss the GS500e/f, not to give each other a hard time.  I found Alpha's posts to be pointless and inflammatory as well, Charlie requesting help and not frustration is completely understandable.

I posted in this public forum because it is dedicated to the GS.  I have found a lot of helpful information here and I appreciate that.  I hoped to find some helpful insight from experinenced gs'rs concerning my current situation.  Even if that responce went something like this..."I have split my cases and didn't have problems reassembling with the original bolts."  Or "You should be able to re-use the original bolts without problems.  Not sure why yours broke.  Sorry to hear your bolts broke."  Or even.  "You are supposed to replace all case bolts after you split the cases!"
 

Give it some time, cosmiccharlie. You'll likely get helpful and mature responses (like SmartDrug's) after the children have gone to bed.  

And sorry to hear your bolts broke. 

Since you followed the Clymer to a "T" you must already know that the torq spec for the 6mm length bolts are half the value of the 8mm length bolts and I am wasting my breath.




psssst....fess up, you snapped the short bolts.