Stud Not seating correctly

[Striker1423]

The stainless steel studs install is going good okay so far except for one of the locating studs for the barrels. It's sitting a thread or two higher than its counterpart on the other side of the case.

I've cleaned the hole, chased the threads, everything is perfect. Is it possible Suzuki just didn't drill the hole deep enough?

[Striker1423]

The background studs are all two or so threads high as well, but when I compared the new studs to the old, the thread count was higher in the new ones so it makes sense for those ones.

[m in sc]

trim a few threads off. 

[teazer]

Funny you should find that.  I have just fitted a set of BDK TItanium studs and they are just like yours - too freeking long. I left mine like that but in retrospect I might have been smarter to drill and tap the cases to take the longer that stock studs.

By any chance have you measured or compared the thread length to be sure they are longer.  It's possible that the threads are "fuller sized" and may be bottoming out in the threads which are not full size to the end. WHen a hole is tapped, the tap has an amount of taper, even a bottom tap so the last few threads are not fully machined.  If the stud has slightly tapered end to the threads, it will potentially sit deeper in the case. And it that wasn't the clumsiest explanation you ever read, I will try and confuse you more later.....

[Striker1423]

So when I inspected the hole, it actually looks like the top of the steel insert is exposed. My guess is this was a through hole at one point in the machining process.

I trimmed 3 threads off and it sits almost as close as the first one now.

All good now.

On another note the bottom end is being rinsed out good. Without using a mallet I can't get the crank out, so I'm working around it and just flushing the bottom out and pulling the oil recirculating tubes to drain.

Also ran a ball hone down the cylinders 7 or 8 quick passes to clean up residuals.