Removing cylinder/damaged engine bolt?

[Ixion]

Good stuff. Piston rings are normal for a four stroke. Two strokes will normally be pegged.

A suggestion. DO not repeat the 'stickj it down with super gungy gunge' idea when reassembling.

A new gasket and a light coating of grease should suffice, if the surfaces be sound and true. Or at most a light (that's LIGHT) smear of Hylomar of some other quality jointing compound. NOT that vile orange silicone stuff.

If the mating surfaces are damaged, best to try to remedy it. And use a torque wrench on the head.

[mikeey01]

Done. Renegade Master came over, we jacked the bike up and tied the barrels to the roof, lowered the jack to increase the tension and gave it a few good whacks.

Great stuff and good on ya Renegade master for helping out!

Or at most a light (that's LIGHT) smear of Hylomar

Yep that's great stuff...I've used it for years and I swear by it. Sometimes goes by the nickname blue.

[xwhatsit]

So at the end of the day you mostly suspect a combination of those crispy-looking exhaust valves and a very tired camchain causing rattles and perhaps erratic timing?

What a clever idea with the ropes

[Magua]

So at the end of the day you mostly suspect a combination of those crispy-looking exhaust valves and a very tired camchain causing rattles and perhaps erratic timing?

What a clever idea with the ropes

Sounds about right combined with those seals between the manifold and carb, yep.



Question, using a helicoil you have to drill out the hole first. Wouldn't I lose a lot of files into the bottom end of my engine? :S

[xwhatsit]

Sounds about right combined with those seals between the manifold and carb, yep.

Ah yes they did look pretty flat, didn't they.

Question, using a helicoil you have to drill out the hole first. Wouldn't I lose a lot of files into the bottom end of my engine? :S

If you're very careful... I did a helicoil into my cylinder head while it was attached to the engine. Is it a blind hole into the crankcase? Or does it go all the way through? If it goes all the way through you might be in the poo, but if not, you could use some rags to stuff up the gaps around the pistons.

Or maybe drain the oil, bolt the engine to your roof, and drill upside down?

[The Stranger:Me]

What could cause those few threads to fill in as they have?

Galling or cold welding.

[xwhatsit]

You mean this stuff? http://en.wikipedia.org/wiki/Cold_welding

It is now known that the force of adhesion following first contact can be augmented by pressing the metals tightly together, increasing the duration of contact, raising the temperature of the workpieces, or any combination of the above.

That all sounds good, and the scraping of metal on metal when the bolt was screwed in would scrape away the oxide layer, but what would cause the vacuum needed to actually start the welding process?

[gatch]

Question, using a helicoil you have to drill out the hole first. Wouldn't I lose a lot of files into the bottom end of my engine? :S

yep as the other dude said if its a blind hole your sweet just keep your spindle speed low so chips don't fly everywhere, if its a through-hole, can you fit a vacuum cleaner nozzle in there ? did that at work once, worked sweet, when you use the tap you can cover it in grease, just go a few turns at a time, back it out, wipe off grease and go again..

[Magua]

yep as the other dude said if its a blind hole your sweet just keep your spindle speed low so chips don't fly everywhere, if its a through-hole, can you fit a vacuum cleaner nozzle in there ? did that at work once, worked sweet, when you use the tap you can cover it in grease, just go a few turns at a time, back it out, wipe off grease and go again..

Vacuum cleaner nozzle? It's a through hole.

Edit:. that's a photo of a different hole, they're not through holes. I don't trust myself with a drill though, think I'll have to get it to an engineer's shop.

[speedpro]

You'll need to get the little tang off the bottom of the helicoil without dropping it in as well.

The reason the thread seized up is the same reason the barrel was hard to remove, it's been together a long time. A good way to ease future disassembly problems is to put loctite on all the threads. Not only does it lubricate the threads as you assemble it but it holds the thread tight and the loctite stops corrosion. You only need 222 or whatever it is now. I like to use Loctite on the base gasket as well. Just the faintest smear of something like 555. I like the loctite gasket compounds as they don't set except in the joint and therefore can't flake off and block an oil gallery to the head which historically has been a bit of a problem with hondas being worked on by beginners. As has been said - keep away from silicone goo, it's wrecked many a good engine.

edit: Honda fed the oil up one or more studs on these motors I think, it was a typical thing to do anyway. so you have to be double double careful. Just take the cases apart, it ain't hard and it eliminates a lot of potential problems. Nothing like giving it a good flush out with the garden hose to get rid of swarf etc.

[speedpro]

Vacuum cleaner nozzle? It's a through hole.

Edit:. that's a photo of a different hole, they're not through holes. I don't trust myself with a drill though, think I'll have to get it to an engineer's shop.

This stud hole has an oil gallery feeding it, see the hole to left within.

[Magua]

This stud hole has an oil gallery feeding it, see the hole to left within.

Yeah I noticed. Funny that the bolt that came from the hole with the broken thread has an "oil control washer", but no oil gallery.

[gatch]

oh thats a bugger, i thought it would just be straight into solid metal, forget the vacuum thing...

[Magua]

Yeah I noticed. Funny that the bolt that came from the hole with the broken thread has an "oil control washer", but no oil gallery.

It's looking like I've lost one of those damn washers, and it's not as simple as popping up to the bolt shop to get another.

Who can I get to make me another?

Edit: Nvm, I'll go to the wrecker. Duh!

[xwhatsit]

It's looking like I've lost one of those damn washers, and it's not as simple as popping up to the bolt shop to get another.

Who can I get to make me another?

Edit: Nvm, I'll go to the wrecker. Duh!

Hahah, you need more ice-cream containers.

So I'm confused. The dodgy hole doesn't have an oil gallery, and is a blind hole? If so, that's a piece of piss. Don't have to worry about the tang on the helicoil either (don't most people just leave them in place if space permits?). I kept drilling a little bit, then dunking the drill bit in a tub of old engine oil, which meant most of the swarf stuck to it and kept the drill bit lubed anyway. Same deal with the tap. It's really not hard to do, you just have to keep the drill bit dead straight so you don't round out the hole.

But to buy a kit is about $50 -- getting the hole coiled by an engineer would be similar, although you don't get to keep the drill and tap that way. Time to drop the engine out! At least it'll be lighter now