newG 1100g

[azr]

She sounds good from the video Charlie. I'm sure that pooping stuff will disappear once you fine tune the carbs. Too bad about the caliper bolts, I've never had that happen, I never torque them, just on tight, pretty tight to boot. Can't imagine you need Suzuki bolts, anything should do. Axle grease is fine, you don't need much.

[Big T]

Never seize may be better on the new bolts, there may be a bit of corrosion in there

I used allen heads from ACE

[Charlie G]

The PO pointed out that he had broken one bolt on a caliper axle, so I robbed one off the 82 1100 g and dam if it didn't shear. Robbed another one ( axle & bolt) and cleaned out the internal threads with a tap because there was a bit of resistance and it did fine. Thought I'd check the torque on the rest and snapped another. ( insert swearing ). I'll use anti seize and clean the thread out with a tap. It actually says to torque them to 29-40 ft lbs. The second snapped a 20 ft lbs. I'm going to check the length as well. Thanks guys! Nice to have someone else to bounce ideas off of.

cg

[azr]

That's so strange that they snapped, I've never heard of that happening before. Hope you have an easy way of getting them out

[Buffalo Bill]

That one on the right…

Click for a little video of the running bike...... Let me know if it doesn't work.

I got the 83 1100 g I picked up in Sacramento this last winter running. It was running a bit rough but swapped out out the coils off the other 1100 and it's better. Still has a bit of a pop when I rev it and roll off the throttle quick. I'll sync the carbs and bleed the brakes and a quick road test to see where I'm at with the rest.



These are some front caliper axle bolts which are to be torqued to 20-40 ft lbs. I snapped two of them at 20 ft lbs. Do these things get brittle over time? Do I need to buy Suzuki's bolts or will what they have at ACE do? Axle grease,? Will auto caliper grease do fine? A bit of a newbie on some brake items. I could use a bit of advice here. Thanks.

cg

The one on the right looks ready to snap, the threads look stretched apart at the same point the other broke.
You shoulda suspected, and just replaced them all after the first broke.

[Charlie G]

That's so strange that they snapped, I've never heard of that happening before. Hope you have an easy way of getting them out

For the time being I'm robbing off the 82 and I'll see how hard they are to pull apart later.

The one on the right looks ready to snap, the threads look stretched apart at the same point the other broke.
You shoulda suspected, and just replaced them all after the first broke.

Good eye there Bill. The right hand one is the second one that snapped. I was surprised when I came out in one piece.There all getting replaced, with the threads cleaned up in the axles. Nice to see you posting Bill!

cg

[mmattockx]

These are some front caliper axle bolts which are to be torqued to 20-40 ft lbs. I snapped two of them at 20 ft lbs.

Is that torque value wet or dry? If it is dry and you lubed the threads that may explain the failures. The bolt on the right shows heavy necking so it certainly isn't brittle. Is your torque wrench calibrated? Working properly? The only issue you may have with buying generic bolts instead of Suzuki parts is that the generic ones may not be the right grade and may not be strong enough to hold the specified preload amount.


Mark

[Charlie G]

Is that torque value wet or dry? If it is dry and you lubed the threads that may explain the failures. The bolt on the right shows heavy necking so it certainly isn't brittle. Is your torque wrench calibrated? Working properly? The only issue you may have with buying generic bolts instead of Suzuki parts is that the generic ones may not be the right grade and may not be strong enough to hold the specified preload amount.


Mark

I didn't put any lubricant on these bolts. These snapped at 50% of the max value....

[londonboards]

Hey Charlie - you copying my vids? White T and a bottle of beer in the pic.

Good on ya bro!!

Greetings

[mmattockx]

I didn't put any lubricant on these bolts. These snapped at 50% of the max value....

Curious. Sounds like it is time for a new set of bolts just to be sure of what you have. Is it possible a PO over torqued the bolts in the past and you were just the lucky guy to have the failure complete itself on your watch?


Mark

[Charlie G]

Hey Charlie - you copying my vids? White T and a bottle of beer in the pic.

Good on ya bro!!

Greetings

Another good eye there. It was an intentional copy and it has lead to success so far! Cheers.

Curious. Sounds like it is time for a new set of bolts just to be sure of what you have. Is it possible a PO over torqued the bolts in the past and you were just the lucky guy to have the failure complete itself on your watch?


Mark

New bolts for sure. Thanks.

cg

[Charlie G]

Hope this video works...

First ride. Still have to sync. Special MotionPro tool will be here tomorrow afternoon. Ride smooth as can be. Not quite as much power as I would have expected. Replaced all the bolts on the calipers and re-torqued all bolts on the front end which were hand tight. Glad I checked before I rode.

cg

[posplayr]

The one on the right looks ready to snap, the threads look stretched apart at the same point the other broke.
You shoulda suspected, and just replaced them all after the first broke.

Exactly what I was thinking 20 ft-lbs to break? Bolts have all been over stressed and I would trust none of them. And for caliper bolts I would buy oem and not worry about it. Otherwise look for used where there was no idiot over torquing them.

[azr]

Congratulations Charlie!! I was a bit worried there but you showed me, nicely done. Hows the engine look? no leaks are anything like that? any smoking?

[Charlie G]

Congratulations Charlie!! I was a bit worried there but you showed me, nicely done. Hows the engine look? no leaks are anything like that? any smoking?

It's not ready to ride to BC just yet. I'm trying to curb my optimism at the moment. I haven't ridden it enough yet to know too much for sure. No obvious leaks or smoke. When I got back yesterday the pipes had blue marks where I hadn't noticed before. I suspect hot pipes show off bluing more than cold ones in a dark garage. We'll see. Want to sync the carbs tonight and do a compression test. Not real sure 2 & 3 are firing at full strength and want to see where they are compression wise. Thanks for the comments.

cg