SuzukiSavage.com - Oil Cap Seal

ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Oil Cap Seal 01/28/23 at 13:19:47 Hey Savages. I’ve got the dreaded oil cap seal leak on my 2004. I read the posts and saw the pics of the repair. I’m afraid I’ll screw something up. Any Savages out there in the Houston area that have done the repair or someone in the Houston area that could? I can do the basic grunt work involved. I just don’t trust my motor skills well enough.
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buster6315 Senior Member Offline SuzukiSavage.com Rocks! Posts: 384	Re: Oil Cap Seal Reply #1 - 01/28/23 at 13:55:08 Are you referring to the 'head seal cap'?
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: Oil Cap Seal Reply #2 - 01/28/23 at 14:27:50 Yes. The lil sob behind the exhaust port under the top end of the valve train.
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5401 Manteca , CA Gender:	Re: Oil Cap Seal Reply #3 - 01/28/23 at 17:42:03 See Verslagen in Market place , his plug is easy to use
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5401 Manteca , CA Gender:	Re: Oil Cap Seal Reply #4 - 01/28/23 at 17:45:01 Or we can send JOG over there with his backhoe
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Dave

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Re: Oil Cap Seal
Reply #5 - 01/29/23 at 03:44:59

ThumperPaul wrote on 01/28/23 at 13:19:47:

I’m afraid I’ll screw something up.

One issue you have to be very careful while doing - is "snugging" up the 6mm bolts that hold the head cover on. Those are very small and the threads in the head and cylinder are aluminum......they only take a small amount of torque and the threads strip easily if you apply too much torque. There are 3 long bolts on the right side that extend down into the cylinder (once goes into the oil galley)....if you strip those the job becomes far more difficult.

It is essential you borrow or buy a small torque wrench - using a 150ft/b torque wrench to tighten screws with a value of 5.9-8.8 ft./lbs will not work (my own personal 150 ft/lb. torque wrench is pretty worthless below 25 ft./lbs as the "click" is faint and not easy to hear or feel).

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« Last Edit: 01/29/23 at 15:22:33 by Dave »

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: Oil Cap Seal Reply #6 - 01/29/23 at 05:00:31 Thanks Dave. Exactly why I’m afraid to go it alone. I have a small torque wrench, but it’s all the details and nuances that would probably get me in trouble.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Oil Cap Seal Reply #7 - 01/29/23 at 14:52:16 I'll perform the burial, but I'm gonna need someone to blow taps.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: Oil Cap Seal Reply #8 - 01/29/23 at 15:56:16 Haha Justin. You and Ruttly can bring the backhoe with Bubba. I'll be waiting...
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TrevorKlein Junior Member Offline SuzukiSavage.com Rocks! Posts: 59	Re: Oil Cap Seal Reply #9 - 02/21/23 at 00:22:35 Firstly, try to find out real reason of oil leakage after that you must consult to mechanic instead of waiting for someone experienced rider.
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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10801 Oklahoma Gender:	Re: Oil Cap Seal Reply #10 - 02/21/23 at 03:29:27 Isn’t Springman in Houston ?
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ThumperPaul

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Re: Oil Cap Seal
Reply #11 - 02/21/23 at 04:11:48

Thanks Lancer.

Trevor - “Why” = it has served its useful life. Its actually considered ‘maintenance’ by Suzuki, but the often early failure is a known and common issue with our bikes. I try to do my own work and avoid expensive mechanics that usually aren’t as familiar with our bikes as the people here on this forum. Getting some help or a recommendation here is the best place to start.

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TrevorKlein Junior Member Offline SuzukiSavage.com Rocks! Posts: 59	Re: Oil Cap Seal Reply #12 - 02/28/23 at 00:48:06 Engine pressure can stress up the oil filler cap which can split or damage it. You can loose its bolt with small screw driver and change its washer and after that fix the cap over it again. Avoid breaching the cap if its not damaged then.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: Oil Cap Seal Reply #13 - 02/28/23 at 04:12:02 Trevor, It’s not the filler cap. It’s this cap plug discussed here in the Technical resources library. I posted my question here so as not to muddy up the technical resources library with a lot of babble back and forth. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1099227295
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: Oil Cap Seal Reply #14 - 02/28/23 at 04:32:42 PS - I got it done over the weekend with a lot of patience (not my strong suit), 14 F-bombs, finger crossing, and a 12-pack when I finished. I’ve only put 20 miles on her since the repair, but she’s running fine and no leaks so far. I did use Red Permatex, and creating a cardboard diagram of where every little part goes is brilliant!
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