|
Post by Glenn RE5 on Jan 20, 2013 16:05:13 GMT -5
Hi, having started the bike for the first time in 20 years all was fine for a few mins then coolant started to come out from behind the starter motor well oil/water mix,not a little but a flood! having had very good advice from the good folk on this site it was decided that water was flooding the area behind the clutch casing, having now removed this it looks like a core plug has blown out from behind the counterweight, I can feel where the plug was and its like sharp edges like its like more torn than come out as a hole unit,it looks like i could maybe replace the plug from this side or have a new plug made to fill the hole, any one know what these plugs were for, are they all on the cooling side of the rotor housing ie if one has rusted and burst the i need to change them all, and any tips on getting this counterweight off to get to the plugs looks a nitemare!
|
|
|
Post by HGH 770N on Jan 20, 2013 16:17:00 GMT -5
Glenn , The core plugs are a safety valve to prevent your chamber splitting or side plates worping , Your engine has probably frozen up while in storage and pushed a plug out . I think you can get core plugs from Suzuki UK or from Jess @ RR , you will have to remove counter weight to knock new plugs in square .
BEST Rog
|
|
|
Post by HGH 770N on Jan 20, 2013 16:34:43 GMT -5
41 mm deep socket with a rattle gun is good or a long bar , you will need to put a socket on a extention bar through one of the three holes in the counter weight on to one of the bolt heads that you can see , this will stop the shaft turning while undoing the 41 mm nut . Then you can use a 3 legged puller , Be sure to protect the thead on the end of shaft with a packer. Rog Attachments:
|
|
|
Post by Glenn RE5 on Jan 20, 2013 17:41:57 GMT -5
Thanks for help folks, what are these core plugs made of? could it be that the plug thats gone has rusted and its just holed, its not come out it feels like the middle has blown out, anyway will find out when i get to it, thanks for the help with the puller but ive only taken the clutch cover off and cant get that type of puller on, no room, on your pic looks like you have the inner cover off and its a pic of the flywheel,
|
|
|
Post by mike500 on Jan 20, 2013 17:49:42 GMT -5
core plugs are useuallly steel so when left to stand for a long time they can rust out or go very thin but still stay water tight till the engine is started and as soon water pressure builds up they rupture and if this is your first time with an re5 you should get yourself a genuine suzuki re5 service manual and also the parts manual as they will help u a lot regards mike
|
|
|
Post by goandy on Jan 21, 2013 5:56:15 GMT -5
I replied in the other thread with pretty much what the other guys have already said. D'uh. Anyway, get your clutch assembly, primary chain and points drive gear etc off, then "pop" the 40/41mm nut off (you'll have to measure this to make sure you get the right socket). Once that nut is off, you should be able to see the woodruff key slot in the flywheel adjacent to the eccentric shaft. Seeing as you can't get your puller in there, see if you can swing a decent seized hammer on the flat face of the flywheel opposite to that slot and you may be able to crack or ring it free. This is not without risk of damaging stuff tho- you could even crack your flywheel. I didn't but just thought you should know...
|
|
|
Post by goandy on Jan 21, 2013 6:07:33 GMT -5
One more thing= I can't remember but are there core plugs in the alternator side of the rotor unit? If so, these would need to be replaced as well........
|
|
|
Post by Glenn RE5 on Jan 21, 2013 8:34:14 GMT -5
Ok, have been looking on parts list and the plugs aint listed on either side,, anyone have any or know where i can get some here in uk or maybe r&r have them?
|
|
|
Post by goandy on Jan 21, 2013 9:15:34 GMT -5
Measure the diameter of the hole in mm and that's the size core plug you need. Then try an auto parts shop not sure if Halfords would or not. Brass ones will do.
|
|
|
Post by Glenn RE5 on Jan 21, 2013 9:27:54 GMT -5
oh i understand now most cars have them,there on ebay !, anyone know what size they are in the re5 so i can get them ordered
|
|
|
Post by HGH 770N on Jan 21, 2013 9:59:50 GMT -5
Glenn . 5 Plugs on this side Attachments:
|
|
|
Post by steveuk on Jan 21, 2013 10:00:09 GMT -5
Hi Glenn
the loose core plug i have is 25mm od, and approx 6.5mm thick
steve
|
|
|
Post by HGH 770N on Jan 21, 2013 10:03:27 GMT -5
And 4 plugs this side Attachments:
|
|
|
Post by Glenn RE5 on Jan 21, 2013 14:03:27 GMT -5
well thats cleared things up! so i need 9 if am going to change them all,best thing then is take them all out on the clutch side and see what there like, maybe the bike has been stored with just water in the rad and no coolant when it was in hong kong for 10 years and they have just rusted,
|
|
|
Post by Glenn RE5 on Jan 24, 2013 18:06:48 GMT -5
old core plug ! Attachments:
|
|