Allen bolt for clutch cover too long??

[Johnny K]

I received a set of SS allen bolts for the engine covers from stainless cycles and I have a pic with an allen bolt that is 2 1/2 in. long and wondering if it is to long. I tried all 10 holes and all the old ones I pulled out are not this long. Not sure.

[ptm]

The parts schematics list the length of all the case bolts. The longest on on the '82 850 is 6X45 mm which is a little under 2 inches. It's #19 on the diagram:

http://alpha-sports.com/spst/1982%20GS850G/08.htm

[chef1366]

Weird. I had the same problem. I ended up going to a bolt house to get one. The guy from Ebay didn't believe me. He said he had sold blah blah blah and never had a problem till now. All I know it was too long. Also the chrome cam end cover screws were too short.

[Johnny K]

Thats kinda weird because on the set of the clutch cover I received (4) small ones (4) medium ones and (2) long ones. Sorry for the newb lengths but on the parts schematics list they have sets of (3) (3) (4), ya know?? I tried to folow the best I could by taking a bolt out and replacing it with the length of the allen bolt and when I was almost finished the 2 longest ones did not fit at all. Frustrated.:?

[bwringer]

On the earlier GS850 clutch cover, there are two 65mm screws, and (I think) four 25mm and four 20mm screws. (Please, no more of this filthy talk in inches. The fasteners are specified and manufactured in millimeters.)

In other words, you may have gotten a set intended for an earlier model GS850.

Here's a hint: the length and diameter of a fastener are normally embedded in the Suzuki part number:

An example:
01547-06307 is a 6mm screw, 30mm long

01547-06307 - the diameter

01547-06307 - the length

Easy, eh?

Screws and bolts are specified by the size of the threads, not the size of the wrench or head. You do not include the head when you measure length.

If you're stuck, Ace Hardware and Do It Best Hardware have good selections of stainless allen head fasteners at high prices. Just measure before you leave -- people mix up the bins a lot. The big box home improvement stores have very little metric hardware, and usually no stainless allen heads.

If you like having extras (I do!), McMaster-Carr http://mcmaster.com is an excellent source for larger quantities at good prices. (Cheap fast shipping, too.) They usually come in packs of 25, 50, or 100.

If you only need a few, http://boltdepot.com lets you order whatever quantities you need.

[chef1366]

You do not include the head when you measure length.

That's what she said. ;-) :-D