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23 Jan 2018
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Registered Users
Veteran HUBBer
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Join Date: Aug 2004
Location: dublin
Posts: 101
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Cylinder Removal headeach
So I decided to overahaul the engine on my xt 1998/ 150 000 km.
Basically I'm left with the last nut on the cylinder, the front one in some sort of aluminium, has completely disolved with rust, I'm left with the option to cut it off right close to the crank case with part of the Cylinder!
I have a New Old Stock cylinder to put back in but I'd like to preserve that one if possible.
Anyone has had the experience removinG that particlular nut, I tried the rounded up nut tool, but the nut destroyed itself in aluminium dust, if I'm clear?
Thanks
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23 Jan 2018
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Registered Users
Veteran HUBBer
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Join Date: May 2013
Location: Wisconsin, USA
Posts: 827
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I know which ones your talking about , they're down in those pockets that reach to just above the base . So far mine have all come loose , a good 6 point socket and a bit of penetrant but they've not been severely corroded . About all I can think of right now is taking a torch and heating the crap out of them to get the aluminum soft and possible some smaller size socket 8 or 12 point socket can be hammered on , have done it with some plastics .
.
__________________
'86 XT600/3TB motor,,, '88 XT600, ,,'92 XT600e,,, '08 Husky TE510,,, '05 DRZ463,,, '95 KLX650 ,,,'96 KLX650
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25 Jan 2018
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Registered Users
Veteran HUBBer
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Join Date: Aug 2004
Location: dublin
Posts: 101
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Thank..tried, the 8 socket eat the aluminium!. I'm left with cutting the cylinder and studs!
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5 Feb 2019
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Registered Users
HUBB regular
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Join Date: Sep 2008
Location: Hartlepool
Posts: 77
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I had this problem twice on my 3AJ rebuilds, I used my vibrating multi tool to cut through the offending stud.... takes a while and you may use a couple of blades, but it does the trick
Sent from my SM-T813 using Tapatalk
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5 Feb 2019
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Contributing Member
Veteran HUBBer
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Join Date: Jul 2005
Location: Wirral, England.
Posts: 5,673
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Try heating with a MAP gas plumbers torch. Nothing else DIY will get it near hot enough.
If still no joy use a die grinder to shave the nut away. If you're luck you can drive off the out shell of the nut once a face is ground off.
It's like tunnelling out of jail. It takes time. Keep chipping away
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Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.
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