Mystery bolt? - Kawasaki Versys Forum
 
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post #1 of 17 (permalink) Old 12-20-2011, 01:52 PM Thread Starter
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Mystery bolt?

Went to go change my oil out for the first time this weekend. Never done it on the V, only my 500R. I looked for the oil drain bolt, and thought I found it. It was in an odd place, but it was a big bolt with a copper crush washer on it, so I gave it a go. As I cracked the seal, I heard a hissing sound like when you break vacuum on a coolant system. Turns out it certainly wasn't the bolt I was looking for. I put this mystery bolt back in its hole and snugged it up. So far I haven't noticed any ill effects, but there is a bolt on the 500 that you don't remove, period, and I'm hoping this isn't one of those. I spent a good hour scanning the parts diagram looking for a description of this thing, but it doesn't seem to exist. Does anyone know what this bolt is for? It sits immediately next to what I'm guessing is the wire for the oil sensor on the bottom right side of the engine. It's below the two holes that you remove the caps from to position the cams for a valve service. It's also the only one in that area with a copper crush washer. Help!
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post #2 of 17 (permalink) Old 12-20-2011, 02:19 PM
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You can download the service manual here if you have not already done so.

http://www.kawasakiversys.com/forums...ead.php?t=2846
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post #3 of 17 (permalink) Old 12-20-2011, 02:40 PM Thread Starter
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Originally Posted by Sprocket View Post
You can download the service manual here if you have not already done so.

http://www.kawasakiversys.com/forums...ead.php?t=2846
Thanks, already spent a while looking through that too. The bolt doesn't seem to be part of any repair or maintenance procedure that I could find. I'm pretty good at finding parts in the ronayers fiche, but this one has me stumped. If it weren't for that crush washer, I would have just ignored it....
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post #4 of 17 (permalink) Old 12-20-2011, 02:50 PM
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Take a picture pointing it out and post it and you should get a quick answer.


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post #5 of 17 (permalink) Old 12-20-2011, 03:03 PM
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Under "Crankcase/Transmission" page 9-17, I found this written:
"The upper crankcase bolts have copper plated washers, replace them with new ones."
If you look at the two flange-head bolts slightly forward of the one you removed (they're each in a bit of a cavity), you can JUST see a 'copper plated washer'.

I BELIEVE you just removed or loosened an "upper crankcase bolt".

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post #6 of 17 (permalink) Old 12-20-2011, 03:13 PM
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What the hell were you thinking?? Those bolts are above your oil level.

That's a lower crankcase main bolt. It's one of 6 larger M9 bolts which are loosened last in sequence after the M6 and M8 bolts when splitting the crankcase. It is torqued to 32 ft-lbs. The M9 bolts have copper plated washers which are replaced when bolt is reinstalled, with molybdenum disulfide oil solution on both sides of the washer and on the threads of the M9 bolts.
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post #7 of 17 (permalink) Old 12-20-2011, 03:20 PM Thread Starter
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What the hell were you thinking?? Those bolts are above your oil level.

That's a lower crankcase main bolt. It's one of 6 larger M9 bolts which are loosened last in sequence after the M6 and M8 bolts when splitting the crankcase. It is torqued to 32 ft-lbs. The M9 bolts have copper plated washers which are replaced when bolt is reinstalled, with molybdenum disulfide oil solution on both sides of the washer and on the threads of the M9 bolts.
Got a little confused is all. I'm used to working on the 500 on the center stand, and there's only one thing under there with a crush washer. Things look very different under the V on the sidestand. Won't be making that mistake again! Your last comment is odd, though. When I pulled the bolt, there was only a small amount of oil on the inner side of the washer, and the rest was absolutely bone dry. Should I leave well enough alone, or replace the washer and lube the threads even through they came dry from the factory?
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post #8 of 17 (permalink) Old 12-20-2011, 03:35 PM
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Molybdenum disulfide oil solution is applied upon assembly, then mostly dries off... Just retorque it to 32 ft-lbs and keep an eye on it for any oil leak. It should be fine. If it ever does leak, replace the washer and reinstall it as directed.
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post #9 of 17 (permalink) Old 12-20-2011, 04:45 PM Thread Starter
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Boy you guys are rough I'll never claim this as my finest moment, but next time.. more caffeine before wrenching early on a Saturday!
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post #10 of 17 (permalink) Old 12-20-2011, 04:52 PM
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within the question, the answer is often found.
Tiger's deceased father message:

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post #11 of 17 (permalink) Old 12-20-2011, 05:00 PM
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Doh !


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post #12 of 17 (permalink) Old 12-20-2011, 08:08 PM
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I'm almost positive I know the bolt you are talking about because I did the same thing. Is it under the stator, right around the front of the shifter? I snugged it back up haven't had any issues.
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post #13 of 17 (permalink) Old 12-20-2011, 09:07 PM
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I'm almost positive I know the bolt you are talking about because I did the same thing. Is it under the stator, right around the front of the shifter? I snugged it back up haven't had any issues.
Those are the lower crankcase 2 left main M9 bolts. TwoTacoCombo got one of the lower crankcase 2 right main M9 bolts. There are 2 more in the middle for a total of 6, beside all the other surrounding M8 abd M6 lower crankcase bolts.
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post #14 of 17 (permalink) Old 12-20-2011, 09:18 PM
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Boy you guys are rough I'll never claim this as my finest moment, but next time.. more caffeine before wrenching early on a Saturday!
, dont worry no heart feelings.

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post #15 of 17 (permalink) Old 12-20-2011, 09:31 PM
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Well Combo, Next time you are not sure about something on the bike, think:
"Will the guys on the site rip me a new one if...?" lol

Hoping to become a rider soon
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post #16 of 17 (permalink) Old 12-20-2011, 11:30 PM Thread Starter
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Well Combo, Next time you are not sure about something on the bike, think:
"Will the guys on the site rip me a new one if...?" lol
Nah, I was much harder on myself than you guys are. I've rebuilt carbs, done valve checks, the top end on a 2-stroke.. and here I am wrenching on the wrong bolt. I had some choice words to say about that!
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post #17 of 17 (permalink) Old 12-21-2011, 08:34 AM
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within the question, the answer is often found.
As one who has too often asked of myself, “What the hell was I thinking” – I’ve gotta say, that’s downright profound!
.

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