Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
Removing the rocker cover & Cylinder head Removing the rocker cover & Cylinder head
Register FAQ Calendar Today's Posts
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Andy Miller, UK, Taking a rest, Jokulsarlon, Iceland

I haven't been everywhere...
but it's on my list!


Photo by Andy Miller, UK,
Taking a rest,
Jokulsarlon, Iceland



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 9 Aug 2006
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jul 2005
Location: Wirral, England.
Posts: 5,673
Removing the rocker cover & Cylinder head
Do i have to remove or lower the engine for this task ?? Iv just bought a 2003 XT600E and the exhaust studs are very corroded so im replacing them. I need to get the head off though.

On my old XT, you had to drop the engine in the frame, is it still the case ??

Thanks
__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.
Reply With Quote
  #2  
Old 24 Aug 2006
Registered Users
HUBB regular
  
Join Date: Aug 2006
Location: n.ireland
Posts: 49
im only after replaceing the full exaust on a 2002 xte and had the same prob as ur self how i cured ut was to get heat aplied ie oxy accet and heat the nuts red hot and they should come of the studs okay
__________________
2002 xt600e
Reply With Quote
  #3  
Old 25 Aug 2006
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jul 2005
Location: Wirral, England.
Posts: 5,673
Quote:
Originally Posted by dawack
im only after replaceing the full exaust on a 2002 xte and had the same prob as ur self how i cured ut was to get heat aplied ie oxy accet and heat the nuts red hot and they should come of the studs okay
Unfortunatly my problem is much deeper rooted than this now !!

On removing the downpipes i discovered 2 of the studs are heavily corroded and snapped off with only 1-2 mm protruding out of the head !! For gods sake this is a 2 year old bike with 5k on the clock.. the last owner must of been a complete idiot and over torqued them (and im an idiot for not checking)

This is going to be a nightmare ! I planned on drilling the centres out and using left hand thread stud extractors. The problem is that i have to drill hardened steel studs DEAD centre.. i have a pillar drill but the studs protrude at an odd angle so cant use the drill... AHHHHHHHH
__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.
Reply With Quote
  #4  
Old 25 Aug 2006
Registered Users
HUBB regular
  
Join Date: Aug 2006
Location: n.ireland
Posts: 49
sorry to hear wht happened to ya i suggest u start looking into helicoils.
i had a similar prob with a stud on a kmx and used a dremmel to remove its remains. chances r its to well seized and to small (weak) to get any sort of grip with a thread extractor i got lucky with the kmx the hole was a lot bigger than the original stud and there was virgin alloy just wait ing to be tapped

good luck
__________________
2002 xt600e
Reply With Quote
  #5  
Old 25 Aug 2006
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jul 2005
Location: Wirral, England.
Posts: 5,673
Quote:
Originally Posted by dawack
sorry to hear wht happened to ya i suggest u start looking into helicoils.
i had a similar prob with a stud on a kmx and used a dremmel to remove its remains. chances r its to well seized and to small (weak) to get any sort of grip with a thread extractor i got lucky with the kmx the hole was a lot bigger than the original stud and there was virgin alloy just wait ing to be tapped

good luck
well.. i attacked one of the studs today... JESUS what a day.. I drilled out the centre and tried a left hand thread extractor... Wouldnt budge..

I eventually drilled it out until there was only 0.5 of a mil to the thread and the stud (being hardened steel) still wouldnt budge. Ended up having the drill the whole thing out.. Helicoil is going to be my only option now. If that screws up then its new head time.

Its amazing what torment a small thing like a snapped stud can do to your bike !!
__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.
Reply With Quote
  #6  
Old 27 Aug 2006
Registered Users
HUBB regular
  
Join Date: Jun 2006
Location: Adelaide, Australia
Posts: 57
So did you end up taking the head off? If so, did you manage to remove the head without dropping the engine?
I know that you can get the rocker cover off without dropping the engine, as i had to do this to my 02 XT600 a few weeks ago. There was plenty of room between the head and the frame, so i assumed that there would be enough space there to be able to remove the head.
I wouldn't worry about having to buy a new head... if the helicoils don't work for you (can't see why they won't), all you need to do is tap out the stud hole in the head and put an oversized stud in there.
Dan.
Reply With Quote
  #7  
Old 27 Aug 2006
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jul 2005
Location: Wirral, England.
Posts: 5,673
Quote:
Originally Posted by Aussie_Dan
So did you end up taking the head off? If so, did you manage to remove the head without dropping the engine?
I know that you can get the rocker cover off without dropping the engine, as i had to do this to my 02 XT600 a few weeks ago. There was plenty of room between the head and the frame, so i assumed that there would be enough space there to be able to remove the head.
I wouldn't worry about having to buy a new head... if the helicoils don't work for you (can't see why they won't), all you need to do is tap out the stud hole in the head and put an oversized stud in there.
Dan.
I had to lower the engine to get the rocker cover off.. I tried for about an hour to get it off without removing it but to no evail... It even says in my Clymer that you must do this, you must of found some magic technique caus i couldnt do it and I removed everything else.

Yup.. Helicoils my only option now !!
__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.
Reply With Quote
  #8  
Old 28 Aug 2006
Registered Users
HUBB regular
  
Join Date: Jun 2006
Location: Adelaide, Australia
Posts: 57
Quote:
Originally Posted by tedmagnum
I had to lower the engine to get the rocker cover off.. I tried for about an hour to get it off without removing it but to no evail... It even says in my Clymer that you must do this, you must of found some magic technique caus i couldnt do it and I removed everything else.

Yup.. Helicoils my only option now !!
Well, I removed the seat, plastics and tank, undid all the airbox bolts and slid it backwards and removed the carbs. Once this was all off and there was no other crap left on the frame, we undid the rocker cover and if you lift it at the front, you can slide it backwards to remove it. There's not much room, but we did it. The catch is that you have to remove the carbs to make room for sliding the rocker cover backwards...
Cheers, Dan.

Reply With Quote
  #9  
Old 28 Aug 2006
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jul 2005
Location: Wirral, England.
Posts: 5,673
[QUOTE=Aussie_Dan]Well, I removed the seat, plastics and tank, undid all the airbox bolts and slid it backwards and removed the carbs. Once this was all off and there was no other crap left on the frame, we undid the rocker cover and if you lift it at the front, you can slide it backwards to remove it. There's not much room, but we did it. The catch is that you have to remove the carbs to make room for sliding the rocker cover backwards...
Cheers, Dan.

Cheers, ill remember that !!
__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
cylinder head temperature- R80/R100 twins bryan BMW Tech 8 10 May 2009 09:58
Removing LHS cover on electric start Geoff van de Merwe Yamaha Tech 2 30 Oct 2003 18:19
Dommie cylinder head mikechips Honda Tech 2 13 Oct 2003 15:22
Cylinder head studs Sean Kelly BMW Tech 6 15 Mar 2003 20:41
Rocker Cover Gasket leak JNTaylor KTM Tech 3 26 Mar 2002 21:24

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

ALL Dates subject to change.

2025 Confirmed Events:

  • Virginia: April 24-27 2025
  • Queensland is back! May 2-4 2025
  • Germany Summer: May 29-June 1 2025
  • CanWest: July 10-13 2025
  • Switzerland: Date TBC
  • Ecuador: Date TBC
  • Romania: Date TBC
  • Austria: Sept. 11-14
  • California: September 18-21
  • France: September 19-21 2025
  • Germany Autumn: Oct 30-Nov 2 2025

Add yourself to the Updates List for each event!

Questions about an event? Ask here

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 01:01.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top