Nightmare.

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PaulD
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Nightmare.

Post by PaulD » Sun Sep 29, 2019 8:44 pm

We’re all doomed! well I am anyway :roll:
I got stuck in today re-torquing the head etc. When I built the motor up with the new head & cams I bought from John R the exhaust cam didn’t have a sprocket so I re-used the one off my knackered cam. HOWEVER it seems Suzuki in their infinite wisdom decided to use 6mm bolts to hold the sprocket onto the cam on some bikes and 7mm on others?
When I first realised the new cams where different (the 6mm bolt fell through the hole :lol: ) I thought someone had re-threaded it in the past and the thread looked like an old BSF thread. I had a selection of imperial nuts and bolts and found a couple that seemed very close which I used. Now I’m sure it would have been ok but since finding out Suzuki made some with 7mm threads it’s been playing on my mind. Imagine the carnage if those bolts came out at 8000rpm :o
I’ve since bought some high tensile 7mm bolts and I was going to swap them when I tightened the head down. I removed my bsf bolt and just to make sure the thread actually is 7mm I screwed the new bolt in from the back to check, sure enough it is. So I unscrewed it and dropped it down the camchain tunnel :oops: feckk feckk feckkity feckk feckk feckk!
then I realised that the holes in my sprocket are 6mm clearance so my shiny new bolt won’t fit feckk feckk feckkity feckk feckk feckk! that meant removing the cam so I could drill the holes out to the correct size. I backed the tensioner off and removed the cam caps and one of the holding bolts sheared off flush with the head! feckk feckk feckkity feckk feckk feckk!
So I’ve now sorted the cam sprocket out and that’s good to go, I’ve got to get the snapped off bolt out and see if I can fish the bolt I dropped down the camchain tunnel with my magnetic pick up tool or it means the sumps got to come off again. After all that I can do the original job I started and tighten the head down and check the valve clearances. This bike is driving me feckkin nuts :lol:
There rubbish them Jap bikes lad they won't last five minutes! you want to get yourself a nice Royal Enfield!
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Re: Nightmare.

Post by johnr » Sun Sep 29, 2019 9:27 pm

ffs paul, if it werent for bad luck youd have no luck at all! ive an endoscope camera if you want to poke it down there to locate fish the bolt prior to going fishing, but be careful not to turn the engine over in case the missing fastener has dropped onto the camchain sprocket or close by.
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Re: Nightmare.

Post by PaulD » Mon Sep 30, 2019 4:32 am

johnr wrote: ↑
Sun Sep 29, 2019 9:27 pm
 ffs paul, if it werent for bad luck youd have no luck at all! ive an endoscope camera if you want to poke it down there to locate fish the bolt prior to going fishing, but be careful not to turn the engine over in case the missing fastener has dropped onto the camchain sprocket or close by.
I’ve got a feeling I’m going to have to drop the oil and remove the sump plate to find it John. I’m not sure an endoscope would see much in a sump full of 10-40 mineral oil but thanks for the offer 8-)
There rubbish them Jap bikes lad they won't last five minutes! you want to get yourself a nice Royal Enfield!
A quote from my old dad 8-)

I started out with nothing and I’ve got most of it left!
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Re: Nightmare.

Post by Uncle Bob » Mon Sep 30, 2019 11:11 am

OMG, Paul! I hope you can get it out with a magnet on a stick. Once Oil out John's endoscope idea would be good.
Would it drop through to the sump? From what I saw when i cleaned mine, I didn't think it would from where it dropped.
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Re: Nightmare.

Post by PaulD » Mon Sep 30, 2019 11:23 am

Well the thing is I didn’t actually see it drop down the tunnel but the noise it made was definitely metallic and as I’ve got a plywood floor I’m certain it didn’t hit that? So I know exactly what’s going to happen, I won’t be able to find it with the magnet and I’ll have to drain the oil & remove the sump only to find it’s not there but nestled in the exhaust somewhere :oops:
You will be able to hear the scream from where you live :lol:
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Re: Nightmare.

Post by johnr » Mon Sep 30, 2019 6:41 pm

check its not dropped on top of the exhaust then.
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Re: Nightmare.

Post by PaulD » Mon Oct 07, 2019 8:45 pm

Well some progress, I managed to get the snapped bolt out of the head after two days of careful drilling ever larger holes up to 5mm which is the tapping size for a 6mm thread and then VERY carefully re tapped the hole. I was paranoid about getting any swarf in the motor but judicious use of rags and using grease as cutting compound I’m sure I got it all. I’ve now re-torqued the head down, fitted the cams and done the valve timing, all that’s left to do is check the valve clearances and fit the cam box cover.
Fingers crossed the bitch starts to behave herself now :oops:
There rubbish them Jap bikes lad they won't last five minutes! you want to get yourself a nice Royal Enfield!
A quote from my old dad 8-)

I started out with nothing and I’ve got most of it left!
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Re: Nightmare.

Post by PaulD » Wed Oct 09, 2019 4:45 pm

Right the bike is finally back together and running as it should. I’m not going to curse it like the last time but keep your eyes open for plumes of smoke in the NW :roll:
She’s also got a new name, I’m ditching Pussy Galore and as she’s behaved like Satan’s daughter the new name is Beelzebitch :lol:
There rubbish them Jap bikes lad they won't last five minutes! you want to get yourself a nice Royal Enfield!
A quote from my old dad 8-)

I started out with nothing and I’ve got most of it left!
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