DragBikeMike
Serious Thumper
   
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SuzukiSavage.com Rocks!
Posts: 4471
Honolulu
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It will easily handle the factory service manual spec of 6 - 8.5 ft-lbs. On the 1/4" grade 8 bolts, I go past that a bit. A 1/4 inch grade 8 bolt should be torqued to about 9 ft-lbs with lubricant, 10 ft-lbs zinc plated, or 12 ft-lbs plain & dry. The torque wrench is essentially a way to measure the friction in the fastening system. Lube the threads and you use less torque because there is less friction.
Note: zinc plating is considered a form of lubrication.
The weak link in this system is the aluminum internal threads. IMO, the aluminum threads give up over time. The cyclic stress resulting from thermal expansion keeps working at the aluminum threads and eventually they crap out. Of course, they can also fail if the bolt is overtightened, but a correctly designed fastening system will fail on the bolt, not the internal threads. That's why whenever a steel bolt is used in an aluminum component, there's like at least double the length of engagement. I suspect the Suzuki design department has an army of engineers that stay busy all day long doin fastener calcs. I'm willing to bet they got the design right. But as I mentioned, over time, the constant increase/decrease in stress as the cylinder and head heat up and cool down fatigues the aluminum internal threads. Keep in mind that when the stress is highest, the assembly is also hottest. The yield strength of aluminum tanks at a pretty low temp.
Drill through and put a nut on the bottom and now you no longer have any aluminum threads to worry about. Even though the length of thread engagement is only about one-fourth of the original design, the grade-eight steel is so much stronger than the cast aluminum that the reduced engagement does not compromise strength. An additional bonus is if there is a fastener failure, it will be the bolt. Install a new nut and bolt, rock-n-roll.
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