Keep busting bolts!

[lordcannon88]

heres an interesting one for you...I am in the process of a major overhaul of my bike (82 1100GL) and i have busted 3 case bolts so far and 2 clutch spring bolts. What gives? the manual says torque to 8 - 9 ft lbs and im doing 8.5. what should i be torquing these damn things to guys?

[Guest]

You might want to buy new bolts from Suzuki.

[reddirtrider]

heres an interesting one for you...I am in the process of a major overhaul of my bike (82 1100GL) and i have busted 3 case bolts so far and 2 clutch spring bolts. What gives? the manual says torque to 8 - 9 ft lbs and im doing 8.5. what should i be torquing these damn things to guys?

Are you using new bolts?

Get a set of new ones, maybe some nice stainless to set off your new motor. They're cheap compared to what you've already spent and they really look good.

[earlfor]

Might also want to have your torque wrench checked for accuracy.

Earl

[asetech]

Make sure you are using the right bolts. If they are to long they are sure to break.

[lordcannon88]

You might want to buy new bolts from Suzuki.

hmm. the only bolts that have been breaking have been original ones. new ones torque properly. ive just been getting hardened stainless ones from ACE.

[duaneage]

I would guess debris in the holes or stressed bolts waiting to break. Also, they could be too long, maybe you put the wrong bolts in short holes?

[lordcannon88]

I would guess debris in the holes or stressed bolts waiting to break. Also, they could be too long, maybe you put the wrong bolts in short holes?

no all the clutch spring bolts are same size. and i made double sure the case cover bolts are in right place because they come in all shapes and sizes...well mostly just sizes. i guess ill just replace all with hardened stainless bolts and torque til it feels tight.

[Old Colt]

I would question the wrench you are using. I find allot of people try using click type wrenches on small fasteners and seem to destroy stuff because they trust their wrench.
If you are using a 1/4" beam type torque wrench then the issue is elsewhere but a 3/8 or larger torque wrench should not be used on small stuff.

Also keep in mind in many of Suzuki's manuals the specs on small fasteners are in error. They call for torques about double what they should be. Someone did not do the conversions right back then.

You are better off with a nice set of 1/4 drive and a short ratchet. Just use your fingertips on the wrench and feel for the torque rise as the fastener seats.

[trippivot]

clean the threads

chase the threads

toss your torque wrench

[duaneage]

Buy clutch basket bolts from the dealer. They are a special type and design of bolt. The manual states they must not be substituted. It is a safety issue.