When it comes to major engine maintenance or repairs, usually the engine covers have to come off or the crankcases must be split. The covers and cases are almost always retained using different length bolts. The repercussions of installing the bolts in the wrong order upon reassembly can be very damaging. This is especially true if you install a bolt that is too short for its location and only a couple of threads engage, ultimately stripping the threads when you tighten the bolt.
So what’s an easy way to keep track of cover or case bolts that are arranged in a pattern of different lengths?
My favorite way to organize these bolts is to take a thin piece of cardboard (think cereal box thickness) and then slit the approximate bolt pattern into the cardboard so that the bolts cannot get mixed up. A picture is worth a thousand words so check out the one below. You need not be an artist to apply this tip, simply slit the pattern, add a couple reference points and you’re done!
If you are looking for more helpful tips and engine building info, feel free to check out my book, The Four Stroke Dirt Bike Engine Building Handbook. You’ll find 301 pages filled with crucial and down-to-earth four-stroke engine building knowledge.
Containing 250 full color pictures, 300 pages of step-by-step instruction, and detailed technical knowledge that can be applied to any make and model, The Four Stroke Dirt Bike Engine Building Handbook is a trusted guide for any expert or beginner.