hands on mechanincal help needed...south central pa

Hey guys,
I tried posting in the Eastern US forum, but didn't have any luck. Also, the member search does not seem to be working. Anyway, I could really use some help getting my bike fixed up. I need to helicoil two valve cover bolts. One of them is an inner, under the frame, and I suppose the engine needs pulled to do that. I have been wrenching on the bike a bit, have done what I can, and do have mechanical experience, but I am mortified of the idea of drilling a hole in into the head of my bike, let alone pulling the engine. I know that it could really use a valve job, carb cleaning and cam chain adj, also, but I really can't afford to take it to the shop. I just want a rider that won't leak to ride to work...If you go look at my post, I do have some services to trade... can anyone give me some help?
On another note I have been trying to get a hold of Cycle Recycle for three days. I want to get new valve cover bolt seals. Do they ever answer their phone? I hate to order these parts from the dealer at almost twice the cost.
Thanks,
Nighttraingirl

 

Is there room to get a close-quarters drill in there to drill the holes for the helicoils?

 

I dont think there is, as you have to use a short allen to put in the bolts. with the cover off that adds another 1½-2" but you'd still need a short drill and a thin offset drill driver.

 

I've heard great things about EDM for removing broken bolts and studs.

You might check with your local machine shops to see who does this and if it can be done with the engine in the frame.

If you have it done, make sure to leave the regulator/rectifier and TCI at home.

 

Then it looks like either the engine must come out or the head needs to come off to drill for the helicoils.

 

If you decide to pull the engine and need a hand let me know. I'm down in MD but would make the drive to help out. I've never drilled a head either but I can atleast help you get it out.

 

Unfortunately, no, I don't see any way to do it without pulling the engine.
MiCarl, I don't have a broken bolt, but the threads are stripped out of the holes. I am not even sure how it happened, because I changed the valve cover gasket last year and I used the torque wrench on it. Once I noticed it leaking, I double checked the bolts, and two of them were just spinning loose. I do have a broken off exhaust stud, but I didn't mention that. It's the least of my worries, and has been like that for years. It's behind the frame, too. :-(

 

I'm in Winchester VA, probably about an hour or so from you. I know from experience that you can pull the head while the engine is in the bike. It's been a long time since I've had a 650 though. I'm a bit confused as to which bolts you are talking about.

 

They are the bolts that hold the valve cover on...I don't want to pull the head off the bike, I think that might be worse than just pulling engine.

 

Have you given Chacal a PM? He has everything you need in stock and will ship proptly.

 

Can you put proper torq on the bolt?
If you can, and it just "works" loose, it's worn threads.
I would try a little thread locker on it. The light duty type. You should still be able to remove the bolt after.