Please help!  Late last week, I broke (in half) one of the three screws that hold in the oil filter (while doing an oil change) in place.  Half of the screw is still located in the engine.  Sorry, I am unable to post pictures - I hope the location makes sense. 

I am unable to unscrew the part left in the engine area out of the motorcycle.  I will take my motorcycle to my local moto mechanic to help me with this aspect (he told me he would weld on a nut then pull it out that way).

My real problem lies with the fact that Suzuki has this OEM $2.88 part on back-order and it may take weeks/months to get. 

My local Suzuki shop stated there were no dimensions for this screw (it's kind of a screw/bolt combination) listed on their parts manual (microfishe). 

Does anyone know where I can find this screw?  Or know the dimensions so I can pick one up at Lowes or Home Depot?

Thanks in advance,

Nancy

When the mechanic pulls out the broken threaded stud, ask him if he has a piece of threaded bar he can cut a short piece off to replace the stud he has pulled out.

If not, take the broken piece to hardware stores and see what they have that matches the thread exactly, then cut a small piece off that if you can't wait on Suzuki to provide the part. A machine shop or engine builder may have a piece of scrap threaded bar they will let you have, or can make you one up.

Good luck!

Nancy,

If there is enough of the post exposed you can extract it yourself using the double nut method (search for it) and avoid excessive labor charges.

A temporary fix, If you really can't wait for the OEM part, is to get a bolt from Home Depot that will fit the hole.  Get a nut as well.  The bolt should be longer then  OEM screw so the nut will fit.  Put the nut on the bolt all the way to the to then put the bolt through the filter cap and screw into place.  Use the nut to tighten the cap down.  Again this is just temporary.

-Porkchop

Take one of the 3 nuts that held on the oil cover and you should be able to find the size at the hardware store.

If it's just a straight measure of threads the whole way through, and you're trying to replace it yourself so what other people have said by going to the hardware store, but buy a bolt that's longer than you need, and screw it in there tight, then use some bolt cutters and snip the head of the nut off, leaving enough threads to get the nut on there. Your other option, if they have them in metric, is to find one of those bolts that don't have a head, they just have a hey key hole cut in the end. If they had one long enough you could just screw that straight in there and be set.

All that is under the assumption that you can get yours out, either by grabbing it with some vice grips if it's actually sticking out enough, or an easy-out, although the bolt is probably too small for that one. If it can't come out one of those ways a mechanic is probably going to have to drill it out, and re-tap the threads for you to use a bigger bolt, or just drill it out, and you could use a heli-coil and possibly use the same size bolt.

I don't know if any of those work, but I know exactly how you feel. I destroyed a couple bolts/threads on my last motorcycle. i've been gentle with this one.

Ooh, and people here like pictures when you describe a problem so we can see what it is we're looking at.

I just came across this completely by chance as well...... http://pantablo500.tripod.com/id10.html

Just ran into this post, I broke one of the studs doing an oil change this morning, get metric cap screws (allan head bolts) 6x1.00 x1.5 they fit perfect with a small lock washer and look great because they are black

I don't know the recommended torque and if I knew i wouldn't use a torque wrench anyway.  Too much chance the wrench would be out of calibration or the user wouldn't feel the click.

Tighten these FINGER tight while holding pressure on the cap to compress the big spring.  Then JUST SNUG them with a box end wrench.  They just need to be tight enough to compress the o-ring and tight enough not to back off. 


I broke and stripped  bolts and studs occasionally when I first started wrenching 45 years ago.  No one is perfect.

You develop a feel for snugness and tightness with experience.  Most experienced BMW techs for example actually develop a feel for nearly every fastener on the bike and they almost never use a torque wrench.  If you use one make sure you torque to LOWER end of spec and make sure you know when the wrench is indicating torque is achieved.  Many people blow right thru the wrench feedback and strip and break things.  Torque wrenches are really useful for preloading bearings and such because feel is difficult there.

Some of these studs have different thread on the end that screws into the engine vs the end you put the nut on.  Not sure about this one, but make sure you have the right thread before you screw anything into the engine.

Quote from: rkjjeep on September 11, 2011, 10:33:37 AM
Most experienced BMW techs for example actually develop a feel for nearly every fastener on the bike and they almost never use a torque wrench.

Oh Really?.....remind me never to go to a BMW shop then....

sledge - i know you were being polite (Thanks!) but it's true - most of them use short wrenches to reduce leverage and tighten by feel - especially on the soft stuff.  The number of drain and fill plugs on BMW's that have had threads stripped by over tightening is unbelievable.  With people who don't understand the feedback signal from most torque wrenches they are usually better off without one.  There are many ways to do this stuff and I chose a long time ago to learn how things should feel and do it that way.  I've never had anything come loose nor have I stripped or broken anything in the 35 years since I finally figured it out.  Others will say the same thing about using a torque wrench, so good for them as well.

Ride safely!

Quote from: rkjjeep on September 11, 2011, 10:33:37 AM
Most experienced BMW techs for example actually develop a feel for nearly every fastener on the bike and they almost never use a torque wrench. 

I presume you are making this statement on the basis that "most" of the experienced BMW techs throughout the world have actually told you this in person?? 

Lets imagine this little scenario.....shall we.

I drop my imaginary R800R off at the local dealers for a repair to the forks, say a fluid leak. I pick it up the next day and am told the job is complete. I ask if all the fixings, specifically the front axlebolt, caliper holding bolts and fork clamp bolts have been torqued up to manufactures spec owing to the safety implications. The answers I get is ...".No....we don't so that Sir, we rely on the tech `guesstimating` them" 

Now......are you saying this happens on a daily basis at BMW shops around the world??

How do you think me or any other experienced motorcyclist or Engineer would react if I was told this?? Do you think BMW themselves allow and condone this sort of practice??

Do you mind if I make a statement?....

I believe yet another BS-er with an over-inflated ego/opinion of himself has joined the ranks of Gstwin 

here is your oil filter cover torque settings 9 to 13 nm or if in U.S.A 83 inch lbs to 112 inch lbs (note inch lbs).
oil drain plug torque settings 20 to 25 nm or if in U.S.A  15 foot lbs to 18 foot lbs( note foot lbs)
Buy your self the highest quality torque wrenches that are available  you will never regret it .Factory manuals are there for a reason  .  G o SUZUKI

Yes, I do mind, and you missed my point completely.  Many home mechanics do not have enough experience to feel the feedback from a torque wrench and they blow right past the torque setting.

I won't tell you any more about myself because you'll just chalk it up to the "over-inflated ego" but I have trained tens of thousands of technicians to USE a torque wrench on very sophisticated machinery.  I would never tell them to hand tighten.  They do this 8-10 hours a day for a living.  MAny more casual users are better off without one.  I know this from 45 years of experience working with people on exactly this type of thing.   

And yes, many older BMW techs freely admit they tighten by feel.  I can put you in touch with several if you like.

I was simply trying to help some of the obviously less experienced here avoid problems.  What exactly caused you to make such a negative statement about me?   That was undeserved. "A BS-er with an over inflated ego"? I was only trying to help. 

Quote from: rkjjeep on September 12, 2011, 03:44:52 AM
Yes, I do mind, and you missed my point completely.  Many home mechanics do not have enough experience to feel the feedback from a torque wrench and they blow right past the torque setting.

I won't tell you any more about myself because you'll just chalk it up to the "over-inflated ego" but I have trained tens of thousands of technicians to USE a torque wrench on very sophisticated machinery.  I would never tell them to hand tighten.  They do this 8-10 hours a day for a living.  MAny more casual users are better off without one.  I know this from 45 years of experience working with people on exactly this type of thing.   

And yes, many older BMW techs freely admit they tighten by feel.  I can put you in touch with several if you like.

I was simply trying to help some of the obviously less experienced here avoid problems.  What exactly caused you to make such a negative statement about me?   That was undeserved. "A BS-er with an over inflated ego"? I was only trying to help.

What people (mechanics) actually do and what they "should" do is two different things.....

Torque specs are given for a reason and should be used.........whether the mechanic does or doesn't is another story......whenever I took a car for an oil change...they always overtighten the oil drain plug....I don't take my cars in for oil change any more...I do it myself.....same with spark plugs...overtightened...resulted in stripped threads in my VW....

A torque wrench is simple to operate....any "professional" can operate correctly....any amatuer with a lick of sense can operate correctly.....always much more accurate than "by hand"....

I work in an airplane repair and service shop....we have lots of torque wrenches...different sizes...different types to fit in different places...we always use the torque wrench when a torque is specified..period...

Anybody doing their own work on their motorcycle should get a torque wrench...and use it....

They you have peace of mind that you won't strip out studs...and parts won't fall off.....be happy! 

Cookie

OK - I'll just respectfully disagree for now and let it go.  You can't just buy one torque wrench given the range of sizes of drive and range of torques.  Nothing wrong with an assortment of wrenches in a shop all properly calibrated to a schedule.  Anybody working on equipment should develop a feel for tightening a variety of fasteners.  I just did not appreciate the demeaning comments I received by simply offering another point of view.   Expecting everyone with a GS500 or any other motorcycle to buy and keep in calibration at least a 1/4, 3/8, and 1/2 drive torque wrench and use them often enough is not realistic.  People that work on their own bikes can and should develop a feel for these things.  I hope this is not another board that thinks the point of view of the most frequent posters is the only correct one.

Quote from: rkjjeep on September 12, 2011, 04:05:25 AM
OK - I'll just respectfully disagree for now and let it go.  You can't just buy one torque wrench given the range of sizes of drive and range of torques.  Nothing wrong with an assortment of wrenches in a shop all properly calibrated to a schedule.  Anybody working on equipment should develop a feel for tightening a variety of fasteners.  I just did not appreciate the demeaning comments I received by simply offering another point of view.   Expecting everyone with a GS500 or any other motorcycle to buy and keep in calibration at least a 1/4, 3/8, and 1/2 drive torque wrench and use them often enough is not realistic.  People that work on their own bikes can and should develop a feel for these things.  I hope this is not another board that thinks the point of view of the most frequent posters is the only correct one.

You are entitled to your point of view...But we were presented with a problem....broken stud....we offered a solution (to prevent problem in the future)....use a torque wrench...simple...fool proof....

You offer a solution of estimating torque....not foolproof (in my opinion)...I have had mechanics over tighten my stuff....because they did not use the specified torque...I try to do most of my own work wherever and whenever I can....I try to to my work the best way I know how to....like using a torque wrench...where the torque is critical to safety,  or to prevent damage to the part...

We hear about the broken studs on the oil filter cover again and again and again.........

The solution is to tighten to specified torque......

To me the cost of and the pain in the A of repairing a broken stud is far offset by buying a torque wrench......

I am also sure that you can tighten the little acorn nuts properly , without breaking the stud..but many can't...so use a torque wrench!!

Cookie

OK now dont make me come down there ... OK take it easy everyone ... and maybe leave this post behind ...
Should do and actually do ... yea big diff ... I personally done like seeing silicon dioxide (sand) in the list of ingredients ... however I have eaten it and not felt much of anything. Lets leave it to that ... experience can trump theory ... or theory can trump experience ... or they can both leave it in the exact same spot like happens most of the time.
Cool.
Buddha.

Quote from: The Buddha on September 12, 2011, 10:45:37 AM
OK now dont make me come down there ... OK take it easy everyone ... and maybe leave this post behind ...
Should do and actually do ... yea big diff ... I personally done like seeing silicon dioxide (sand) in the list of ingredients ... however I have eaten it and not felt much of anything. Lets leave it to that ... experience can trump theory ... or theory can trump experience ... or they can both leave it in the exact same spot like happens most of the time.
Cool.
Buddha.

Right on, Buddha.........I haven't the slightest idea what you are talking about (eating sand )  But right on brother!

Cookie

Sorry to jump in after this issue (to torque or not to torque:-) may have just been resolved with Buddha's astute suggestion to just drop it but I can't resist.  Not saying how anyone else does it but I've never use a torque wrench on my bike or cars except for engine work.  My experienced hands are the equal of any torque wrench for most wrenching and I stand on my vast experience, could be rkjjeep is almost as experienced as me.     I started wrenching on cars at age 16 back in 48 on my cars and customer's cars when I went to work in a garage full time summers and part time winters thru HS and College.  Anybody here with more years of experience please feel free to dissagree with me, all others please follow Buddha's advice.   

I can nip a bolt up to an indicated 40newts 20 times in a row using my calibrated torque wrench and know I will be within 2% of this figure everytime.

I would be utterly amazed if anyone could repeat this by hand alone.....regardless of age or experience. In fact I would be utterly amazed if they are within 20% everytime.

Anyone going to claim they can??