About bolts, screws, fasteners

[roeme]

I'm currently in the process of locally sourcing replacement bolts for my GS'es, since all-weather usage, PO neglect, age and corrosion has done a number on the original bolts (Kits available online often only cover parts of the bike, specify the materiel insufficiently (or are vague about it), etc.).

I already got kits for the clutch and stator covers, those were fine so far, luckily. But there are way more bolts on these bikes that are exposed to the elements.

In the service manual I can only find bolt diameters and torques - no overall length, shoulder length, etc. And the the fact that apparently three different types of bolts are in use: "unmarked", "4" and "7". I am not sure to what standards these adhere (other than ISO thread stuff).

As a specific example, when measuring the valve cover bolts, I got a shoulder length of 18mm, thread about 20mm, M6 thread. That doesn't correspond to "standard" sizes...at least those I've found through a cursory web search :-k

Sooo, anybody have a list of this nature that at hand? Or any tips?

(I don't need internal bolts/screws specs, as those are usually in excellent condition).

 

[Nessism]

The part number for at least some of the bolts specifies the length in the suffix. I'm not an expert on that subject but have read quite a number of threads mentioning this previously.

Regarding bolt markings and strength, I've posted this previously but it bears repeating...

Metric 10.9 = Suzuki "9" = SAE grade 8
Metric 8.8 = Suzuki "7" - SAE grade 5
Metric 4.6 = Suzuki "4" = SAE grade 1 (no marks on head)

Be careful with run of the mill stainless steel hardware since much of it is ungraded and low strength. Most stainless is okay for metric 4.6 or Suzuki "4" bolts, but I wouldn't use them for anything else unless you get the strength information.

 

[Steve]

Building on the example that Ed gave you, you should know that there are TWO part numbers for the cam cover bolts on your bike.

14 of the bolts have part number 01550-06407, and 2 of the bolts have part number 01550-06457.

Look at the second half of the part number, directly after the hyphen. You will see 0640 and 0645. That tells you that it is M6 x 40mm and M6 x 45mm. I am not sure about the significance of the 7 at the end. It might be a head style, finish, supplier, whatever, but the first four digits will give you the fastener size.

The two longer bolts usually go in the front left and right rear positions, where there are locating barrels to keep the cover from moving around. Because the barrels are recessed into the head a few millimeters, those two bolts need to be about 5mm longer.

.

 

[roeme]

Thanks for the info, looks like I'll have to build up a list by measuring and going through the correct parts fiche...

As for bolt strength; I aim to use A4/316 stainless (so I don't have to worry about the occasional drive through the rain). Also, I will get the bolts through industry channels/distributors/manufacturers, adhering to the respective ISO/DIN/SAE standard.

Depending on price (316 could be seen as overkill...), I might go for a lower grade SS. All still in the process of being worked out.

Also researching about Anti-Seize currently, so this'll have to be factored in as well.

 

[bobgroger]

Another thing to remember if you are buying from retail is most of the bolts use a different size head for example an 8mm Suzuki bolt uses a 12mm head, hardware store one is 13mm. Also some Suzuki bolts like Shock fastners are a fine thread that is not available from another source in that particular size so you will end up with some mix-and-match going that route. All fasteners should be available from Suzuki, and are not THAT expensive. They will look good for a decade or 2 if you keep out of the salt.

 

[Nessism]

Mid strength grade A4 hardware has a tensile strength of 800 N/mm2 which is similar to a Suzuki "7" bolt.

A2 hardware would more closely align with a Suzuki 4 bolt, or bolts for non structural parts.

 

[roeme]

Another thing to remember if you are buying from retail is most of the bolts use a different size head for example an 8mm Suzuki bolt uses a 12mm head, hardware store one is 13mm. Also some Suzuki bolts like Shock fastners are a fine thread that is not available from another source in that particular size so you will end up with some mix-and-match going that route. All fasteners should be available from Suzuki, and are not THAT expensive. They will look good for a decade or 2 if you keep out of the salt.

Good to know about the heads. It's not about cheaping out on Suzuki parts, but to build up a bolt cabinet for the garage and to use modern materials. Getting the bolts through industry channels reduces the price significantly anyway, but the price difference shouldn't be much to begin with, I imagine.

Mid strength grade A4 hardware has a tensile strength of 800 N/mm2 which is similar to a Suzuki "7" bolt.

A2 hardware would more closely align with a Suzuki 4 bolt, or bolts for non structural parts.

Thanks for reducing my research time If I'm reading the manual correctly, the 550 have "7" at most.

 

[hannibal]

I used the part number trick to replace the screws on my case covers, valve covers, intake/carb holders, and carb tops and bowls. The rule held true for all of them. The only exceptions were oil filter cover studs where the length appears to be the exposed length of the stud, not the full length. The other exception were long bolts that hold the case halves together. I remember some like 08107 were M8 x 110mm, but if you can't tell a 10 mm bolt from a 110 mm bolt, you probably shouldn't be riding in the first place.

 

[Sandy]

Building on the example that Ed gave you, you should know that there are TWO part numbers for the cam cover bolts on your bike.

14 of the bolts have part number 01550-06407, and 2 of the bolts have part number 01550-06457.

Look at the second half of the part number, directly after the hyphen. You will see 0640 and 0645. That tells you that it is M6 x 40mm and M6 x 45mm. I am not sure about the significance of the 7 at the end. It might be a head style, finish, supplier, whatever, but the first four digits will give you the fastener size.

The two longer bolts usually go in the front left and right rear positions, where there are locating barrels to keep the cover from moving around. Because the barrels are recessed into the head a few millimeters, those two bolts need to be about 5mm longer.

.

Bingo. I knew I had this somewhere on my computer. The last digit is the type of finish. I guess this is as good of place as any to put it.

3=ZINC, OLIVE DRAB
5=BLACK
6=ZINC ,GOLD
7=CHROME
B=BLACK
8=ZINC, GRAY

 

[Sam 78 GS750]

For me ordering from Suzuki isn't about the cost or quality. It's about the time. I have to accept waiting for OEM parts... but to wait 2-3 weeks for some bolts and screws?

 

[chuck hahn]

I use Bolt Depot a lot...


https://www.boltdepot.com/

 

[Guest]

The part number for at least some of the bolts specifies the length in the suffix. I'm not an expert on that subject but have read quite a number of threads mentioning this previously.

Regarding bolt markings and strength, I've posted this previously but it bears repeating...

Metric 10.9 = Suzuki "9" = SAE grade 8
Metric 8.8 = Suzuki "7" - SAE grade 5
Metric 4.6 = Suzuki "4" = SAE grade 1 (no marks on head)

Be careful with run of the mill stainless steel hardware since much of it is ungraded and low strength. Most stainless is okay for metric 4.6 or Suzuki "4" bolts, but I wouldn't use them for anything else unless you get the strength information.

Just the info I needed. Am looking to replace a few NLA bolts on a two stroke from before Suzuki used ?4? & ?7? markings.


?01###? series bolts have no markings & were later marked with a ?4? ==> Metric 4.6
?09###? series bolts were marked with an ?S? & were later marked with a ?7? ==> Metric 8.8