Argh...bloody evil case guards!!

[Detman101]

Grrr.... took a long lunch to mount the bastard case mounts mentioned in my earlier post.

I got as far as mounting the complete right side but the left side (from sitting on the bike) is a total pain in the ass. :evil:
*sigh*
The top UPPER mount hole went on fine but the bottom UPPER mount hole doesn't line up. I solved that by banging the tab in and leaving the stock screw in the hole as seen below.

Then there's the lower engine mount bolt....Jesus..I am stumped at how to fix this one...
No one has a bolt long enough to account for the extra metal the case guard introduces it seems.

The bolt in question also doesn't seem to have a replicant with a longer length.

i've been to two bike shops and one hardware store. I'm trying home depot after this and if that doesn't work I'm cutting the bloody big extension down with my angle grinder and bending the case guard to fit.

if I can't find a bolt to make it work its time to break out the fu<**ng hammer and cutting tools.
:evil:

Lord give me strength and patience...and a sandwich hehe..
Dm of m(a)D

 

[Anonymous]

Detman,

Don't give up hope, yet. And don't get too wild with the hammer, either. There is a better way. Look in the Yellow Pages under "fasteners" and look for a shop that specializes in metric fasteners. You have a standard hex head bolt there and it should be no trouble to find a longer replacement. Take the original in and show the shop guys, then tell them you want the same, only longer. My experience is that bike shops are useless for any non-standard fastener and the hardware stores are pretty bad for any unusual metric fasteners (which includes most of our bike stuff). The industrial suppliers are the way to go for this stuff.

Mark

 

[AOD]

Detman, here is what i suggest. First, try grinding the metal on the case gaurd down, so that there is less 'thickness' to it. that might help some of the bolts reach.

however, i know this from experience, you dont really need those front motor mounts that much. my old 550 doesn't have them...period. the engine still has four rear mounts, and two lower mounts....plenty of support for the engine.

keep looking around...you'll find a solution. as a last resort, you may have to tap the holes to a standard size, and use a standard bolt instead of metric.

~Adam

 

[Detman101]

Thanks guys. I will try the "Fastener" store if I can find one. After that I am going with another size bolt that will fit the hole but is longer. Even if its not the same type as the original. I'm so bloody tired of these funky weird bolts showing up. Its happened 4 times already just in my previous work with the rear fender. I think someone may have replaced bolts and put in whatever they could find at the time. I'm highly suspect of this...there is no way this bike could come straight from the factory with such an odd collage of bolts mounted in it.


:?:
Dm of mD

 

[Anonymous]

Case Guards

Case Guards

I got out a 3/8- fine thread tap, ran it through the wedge nut, then bought a standard length bolt and screwed it in... No Problem.
I would not suggest grinding except as a last resort.. MHO

Daniel
Proud Owner of a Newly Revamped 1982 GS1100GL !

 

[Anonymous]

Can you get a length of threaded rod to run straight across the engine? A stack of washers will fix the top picture.

Steve

 

[Detman101]

You're totally right Steve!!
That would work like a charm. I'm not too worried about the top mounts anymore. It's that one evil lower one on the left side that I need to fix.
I don't think i'm going to do the "chop and hammer" method on the left case guard. It might contact the actual case of I did and I don't want that weak stator to take any damage when I drop the bike. So the search continues for a "Fastener Store" in Maryland to replace my evil bolt.


:?
Dm of mD

 

[Detman101]

Re: Case Guards

Re: Case Guards

I got out a 3/8- fine thread tap, ran it through the wedge nut, then bought a standard length bolt and screwed it in... No Problem.
I would not suggest grinding except as a last resort.. MHO

Daniel
Proud Owner of a Newly Revamped 1982 GS1100GL !

Ahhh....I see. So I should look for a 3/8 fine thread bolt in the length that I need and also a 3/8 tap to bore out the hole in the wedge nut eh?
Thanks! I think that is the solution I need. I'm done with running around town like a bloody nut looking for the magical bolt.



Dm of mD

 

[Detman101]

Specs found!!!

M8 x 1.25Pitch x 100mm is what I need!!!
Fastener store guy helped me out and a whole lot more!

The hunt begins!!!


:wink:
Dm of mD

 

[mcycle-nut]

Did you try a bike wrecker? They have all sort of nuts and bolts. 8)

 

[Addy Leung]

Hi Everybody,

I did not read through all the posts about this topic but just share what i can share.

I may have the same problem here but it was solved.

I did buy similar case guard from ebay for my 81' GSX1100EX.
When losing the original 9" mounting bolt, it was broken.

Very very very hard to find ( a month time) a new stainless steel 10" x M10 bolt and nut and it cost HK$50 =US$ 7.

drill a bigger holes on the top mounting hole of the case guard because the mounting holes of it is not good fit to the frame.

now it is installed.

Detmen,
if you need the stainless steel 10" x M10 bolt and nut, I can get one for you and post it to you at all actual cost.

Addy(Hong Kong)

 

[first timer]

try ebay and search fasteners, there are a bunch of stores online that sell all types of hard to find bolts.

http://stores.ebay.com/universalfas...ept18/page5.html?dir=-1&col=4&sotimedisplay=2

ryan

 

[Detman101]

Hi Everybody,

I did not read through all the posts about this topic but just share what i can share.

I may have the same problem here but it was solved.

I did buy similar case guard from ebay for my 81' GSX1100EX.
When losing the original 9" mounting bolt, it was broken.

Very very very hard to find ( a month time) a new stainless steel 10" x M10 bolt and nut and it cost HK$50 =US$ 7.

drill a bigger holes on the top mounting hole of the case guard because the mounting holes of it is not good fit to the frame.

now it is installed.

Detmen,
if you need the stainless steel 10" x M10 bolt and nut, I can get one for you and post it to you at all actual cost.

Addy(Hong Kong)

What could I drill the case with. I tried using a drill but made for metal and it wouldn't put a scratch in that thing.

Dm of mD

 

[Addy Leung]

Detmen,

I didn't drill the case of the engine but drill a bigger hole of on the top mounting tap of the both L/R case guard. so the it is easier to much the existing mounting holes of the frame.

Addy

 

[Detman101]

Right thats what I was talking about.

I can't drill through the case guard.


Dm of mD

 

[Anonymous]

I can't drill through the case guard.

Try using a drill press. Drilling even mild steel by hand is a hard job. Use cutting fluid, sharp bits, and patience. Also, watch the drill speed, too fast is a bad thing and will give poor results and broken bits.

I can't imagine that the guards are anything but mild steel, so it has to be possible.

Mark

 

[Detman101]

Ah, thats the trick then. i was trying to do it with a hand drill on the concrete...*smack forehead*

:lol:
Dm of mD

 

[earlfor]

Its much easier if you use about 4 different size drill bits. Start out with maybe 1/8", drill all the way through, and increase by a couple sizes each time you drill through until you arrive at the finish size you need. A little oil will also help. The larger the bit, the slower the rpm.

Earl

I can't drill through the case guard.

Try using a drill press. Drilling even mild steel by hand is a hard job. Use cutting fluid, sharp bits, and patience. Also, watch the drill speed, too fast is a bad thing and will give poor results and broken bits.

I can't imagine that the guards are anything but mild steel, so it has to be possible.

Mark

 

[Anonymous]

You're totally right Steve!!
That would work like a charm. I'm not too worried about the top mounts anymore. It's that one evil lower one on the left side that I need to fix.
I don't think i'm going to do the "chop and hammer" method on the left case guard. It might contact the actual case of I did and I don't want that weak stator to take any damage when I drop the bike.

So the search continues for a "Fastener Store" in Maryland to replace my evil bolt.

:?
Dm of mD

DM of MD,

Maryland Metric in Reisterstown Md.

Cycle Parts Discounters in Woodlawn Md. Talk to Bill. 410-944-1000
Tell him Charlie sent you.

You can call me (Charlie) 410-997-3802 if you need directions or a helping hand.

 

[mcycle-nut]

Just out of intrest, were these case guards for your particluar model? You seem to be going through a lot of hassle, WAY more than I ever did than when I installed mine.