ARGH...how the hell do I get the shaft bolts out

[bikerzx7r1981]

Hi All,

in the process of swapping the gs1000 engine over to the GS1100G engine. How the hell do I get the shaft bolts out, bent two spanner already... think the last owner has lock tighted them in.

any advice on what may help? can i get a blow gun on it

[bwringer]

You need a 12 point 12mm box end wrench ("ring spanner" to you, I think) and a lot of patience.

The bolts do indeed use thread locker -- it's very, very important, in fact.

[srsupertrap]

Break out the mapgas torch and carefully heat up and let it cool off several times. Then try breaking it loose again

[bwringer]

Break out the mapgas torch and carefully heat up and let it cool off several times. Then try breaking it loose again

I personally wouldn't use that much heat with the u-joint and secondary gear seals so close, and the rubber shaft boot in the way.

However, if you're really stuck, you might try heating up the bolts a bit to help soften the thread locker before you remove them. Perhaps some goober used red Loctite.

Also, if you really are bending wrenches, you might simply need to get a better quality wrench. I've never used heat on these -- they do take a mighty effort to get started, but I've never bent a wrench.

[bikerzx7r1981]

I think it' definately red lock tite they have used. I have soaked them with W40 so hopefully it will be easier tommorow.

Did plit the Gaiter on the shaft though, can anyone recommend where I can get one? searched around ebay but can't seem to find one

[hampshirehog]

If they've been fitted with red loctite or the much more evil green (640?) that some people find the need to use, use a good quality ring spanner and give it a sharp tap with a lightweight hammer. The principle is that you're trying to shatter (for want of a better word) the Loctite rather than use the hammer to loosen. Don't bludgeon - tap sharply.

Loctite suggest using heat on both red and green but Brian does point out the perils here.

[srsupertrap]

I think it' definately red lock tite they have used. I have soaked them with W40 so hopefully it will be easier tommorow.

Did plit the Gaiter on the shaft though, can anyone recommend where I can get one? searched around ebay but can't seem to find one

I too agree with everyone's comments. Regarding the torn gaiter I would only use OEM parts. I have found Carolina Cycle http://www.carolinacycle.com/ to be knowledable and priced right. There is a half a dozen other GS part discounters other GSer's use as well.

[SqDancerLynn1]

That's where a 1/2 breaker bar comes in handy

[bwringer]

You can order the boot from a Suzuki dealer, or wherever you prefer to get OEM Suzuki parts -- last time I checked, it was about $18 US. While you're at it, you might order new bolts as well. They're specially hardened and a special oddball length. They also come with a threadlocker already applied.

If you're re-using the bolts, use blue Loctite -- it's definitely NOT optional.

Good point on using a good wrench and tapping it -- you have to shatter the adhesive.

Depending on how badly the boot is torn, you might be able to patch it with Shoe Goo, or some similar rubbery sticky glop. It's only there to keep the weather out.

Persevere, and watch yer fingers...

[bikerzx7r1981]

cheers I will give it ago tommorow,

had a look online and it doesn't show on the parts list of the websites i'm looking on.

I will email a couple

[bwringer]

The boot (and its clamp and spring) is on the "REAR SWINGING ARM" fiche.

The bolts are on the "SECONDARY DRIVE GEAR" fiche.

[apogeecustom]

The boot (and its clamp and spring) is on the "REAR SWINGING ARM" fiche.

The bolts are on the "SECONDARY DRIVE GEAR" fiche.

My spring fell to the ground during dissassembly and I never really identified how it was attached. It was also rusted up and a few inches have since broken off during cleanup and I need to order a replacement. How does it install? The fiche doesn't really indicate. Does it wrap around the boot on the outside similar to the clamp?