Why Do Suzuki Use S*%t Bolts?

Why is it that everytime I do ANYTHING on my '03 650s, the bolts always snap? They did it when I replaced my snow shovel with a Hamicad number plate holder and now they've done it again.

I was lossening the bolt that tightens the cluth lever bracket so I could adjust it, as I hadnt really bothered doing this since I got the bike. Half way through undoing it and CRACK! The bottom half is stuck in the clamp and the top half is in my hand.

Does anyone have any ideas to sort this? I tried drilling the bolt out, but the drill bit has kicked off slightly to one side and left some of the bolt in the clamp. A friend of mine is bringing me his stud extractor home tonight to try that, but if that doesnt work, what if any, are my other options? Hopefully, some of you more mechanically sound riders will have some ideas.

Cheers boys and girls.

[tinpants]

Suzuki (well all jap bikes, actually!) use cr*p fasteners. My advice would be to drill and tap out to the next standard size if possible. Then put a good dollop of copper grease on the new bolt before screwing it in(ooh-er)

suzuki are the worst, copper grease is the way to go.

[Viney]

Just buy a new bracket. Remember this

Big hands small threads. The bolts on the clamps should be 5ftlb's which in real terms is , finger tight then pinch up with a open ended spanner.

I think to date, i have only ever had one bolt snap. I had more trouble when i pro bolted the bike. Now those things are crap.

Was thinking of a new bracket but to get one on I have to take the bar end off (rubber grommet inside bar is cemented in I think! Cant get the bar end bolt back in now as nut that it screws to is loose inside the bar behind the grommet), remove switchgear (one screw for this is about 1cm away from the plastics on the underneath of the switchgear and I dont have the worlds smallest screwdriver to get to it!) and then remove the grips which are glued in place. It seems more trouble than its worth.

Think I might just follow nick lords advise and get someone who is better at drilling than me (as if!!!..... oh, THAT kind of drilling ) and then retap.

Its just so annoying that a tiny little everyday job can cause so much hassle because Suzuki use such cr4p parts. Im never getting another Suzuki ever again.

Tis a very good question. All the bolts which hold on the carb covers on my bike seem to be made out of cheese and have just died on me.

Does anyone know if its possible to replace all these types of bolts with allen head bolts or can I just getter metal bolts from somewhere?

Someone mentioned getting one of the tub 'o' bolts kits and using them.

i have to get new carbs for my bandit thanks to suzukis crappy bolts, and since saturday my indicator is held on with duct tape, as the bulb went and both screws holding on the indicator lens sheared off.

come on SUZUKI it wouldnt cost much more to use decent bolts!

Even BMW's don't use stainless bolts, but at least they wouldn't resort to using a cast rather than forged gear change selector!

Originally Posted by sprocket

Tis a very good question. All the bolts which hold on the carb covers on my bike seem to be made out of cheese and have just died on me.

Does anyone know if its possible to replace all these types of bolts with allen head bolts or can I just getter metal bolts from somewhere?

Someone mentioned getting one of the tub 'o' bolts kits and using them.

I feel your pain

I had a bolt snap off in cam cover (the rad mounting bolt) then my stud extractor snap in the bolt I WISH I just drilled the thing out in the first place. If the screw extractor snaps, you just enter a whole other world of pain. My advice would be to try and persevere with the drill. As for bolts check out http://www.chewys-stuff.co.uk/ he'll do ya a complete set of ss bolts with allen heads (and invest in a tub of coppaslip) I have a set on my bike. Pukka.

Good luck!