Cylinder Juggs Seperating from Crankcase

The juggs are sticking when nearly off the engine on one of the twelve studs for holding down the cylinder head but l put some penetrating oil down the problematic one and leave it overnight. I am pleased getting parts separated with no damage.

 

you've got the patience, you will succeed

 

More progress. That sheathing was jamming some of the cylinder head holding down studs.

 

Awesome

 

We even had electricity, laddie.

 

Please put some thing under the cam chain to stop it picking up crud form the engine casing

 

Good idea there is a small amount of it fell into the crankcase when l removed the cylinders. Going to replace both chains when l split the cases. I will get it meticulously clean before reassembly.

 

Ah Ok - though it might only have been a tope-end rebuild - as you were!

 

The starter chain was hitting the crankcase so l decided to change it, the plastic guide, starter clutch and cam chain. Bike ran great but l had tiny pieces of plastic too a warning sign of the guide going to break up.

 

Next task removing head to jugg studs. I am going to very carefully drill them square taking as much metal out without damaging the threads. Then l will use a hammer and punch around the periphery of the stud to close the opening and move the remaining stud away from it's threads so l can get acetone ATF mix down between the threads. Let it soak a day or two before trying to remove it.

 

Hi everyone not going as planned. Unable to remove damaged studs on cylinder head. What size of drill and tap should l use to refurbish thanks?

 

I was thinking of an M6 helicoil but I am not sure if there is enough metal to drill out a 5.2mm drill bit.

 

Franz, if I were you I'd be taking a 6-pack of beer, the equivalent of US $ 100 in cash, and that set of jugs to my local machine shop and strike up a deal to have that done properly.......lot cheaper than replacing a set of jugs!

 

Yes I am a Carpenter so I am better leaving this alone. I know your right Chacal thanks that is what I will do.

 

Yes in your situation if budget allows, take to a pro. This motor really had some corrosion huh?

 

Worst engine I ever worked on from a corrosion point of view I mean vashtsdaytona. I just don't like giving up on things lol I am tenacious and I fix most things I work on. But it is a great engine mechanically and I need to make sure the head gasket seals so I am going to get the engineering shop to do it, I am not in a rush won't be on the road till 2021 at least.

 

When I don't have the tool, and the tool is so expensive that there's no real prospect of buying one for the odd occasional job, I grudgingly pay the bloke with the tool to do it for me.
Stings a bit, but it's not often.
That applies to spark erosion equipment most of all, if that's what it needs.

 

Yes true l don't mind paying to get it sorted just my local place was shut. Once the spark erosion removes a broken bolt does the old thread remain or does it need re-tapped?

What l have also noticed is that there is no wear that l can feel between the top piston rings and the top of the cylinders. There is a slight roughness due to carbon which l removed with a bit of wood. Don't know for sure what mileage my engine has done but the cam chain tensioner is fully extended.

 

cam chain guides? good bad or ugly

 

The guides look good. I have not checked the bores with instruments but l can still see cross hatching on them.

 

if the guides are good i wouldn't worry about the tensioner

 

Some photographs. Perhaps the guides are worn?

 

The chain is worn with the curve in it in the picture.

 

8 mm stud repair by shop to cylinder head. Engineer thought 8mm were better. More progress.

 

Need stepped M8 to M6 ones now to go through head gasket.

 

Need stepped M8 to M6 ones now to go through head gasket. Or open up the holes in the head gasket with a Dremmel to take the 8mm studs.

 

WOW is that motor dirty

 

Yes it is l am splitting the cases but the dirt will be removed first. Don't want that in the oilways and bearings. Head is fine cam journals etc perfect.