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Discussion Starter #1
Had a loose plug rattle the threads out of Cylinder 1 so I took it to mechanic to install a helicoil but what he did baffled me.

He glued a plug in cylinder 1 with epoxi. The wrong plug that is and the plug doesn't have a removable cap so the coil pack doesn't fit. Spare me the questions about why he did it. I know already, he's a dumbass.

So removing and replacing the head: what do I need to separate the motor from the frame? Tips tricks any help that doesn't require a shop to do.

Secondly, what all am I getting myself into? How hard.. I want to do the rings while I am at it.

Appreciate the help, thank you.
 

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Why can you not work the spark plug back and forth until you break the glue then drill and helicoil the thread? You will need to grab a large bolt with two nuts to use on the large frame to engine mounting bolts. You will need to mount the bike so that it is not relying on the back wheel as it needs removal with the engine coming out. Take plenty of pics for reference on reassembly.;)
 

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Discussion Starter #3
Why can you not work the spark plug back and forth until you break the glue then drill and helicoil the thread? You will need to grab a large bolt with two nuts to use on the large frame to engine mounting bolts. You will need to mount the bike so that it is not relying on the back wheel as it needs removal with the engine coming out. Take plenty of pics for reference on reassembly.;)
That's awesome dude thanks. What size bolt will u need? I'm at work now and can make one.

Do I need to unhinge the swing arm and rear shock?

Will I have to dismount the triple trees and forks?
 

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I think the internal hex size for the mounting bolts are 24mm flat to flat, you will need to remove swing arm and shocker but not need to touch the front end gear at all, hopefully you are able to suspend the frame from the ceiling or similar using a ratchet strap I mounted mine between a multi ladder and a metal cabinet in the garage, 99.9% of electrical connectors are foolproof as they are different but there is one to the injectors which can be swapped with another nearby as I did on reassembly so be careful of that one.
The bike ends up looking like a unicycle with a frame when stripped down remembering that the engine has the rear end mounted off it.
 

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Discussion Starter #5
LOL.. I am over my head on this for sure but I think you have got so pretty good ideas for me to go with.

Am I going to have to pull the jug completely to re-ring? Is it worth doing any upgrades while in there?
 

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Do you really need to re-ring the engine? What mileage is on the engine? Was it blowing smoke beforehand? You may want to have the head worked on for better flow then fit a Power Commander and after market free flowing exhaust to get the gasses flowing, regards internal mods you could go on forever with lighter stronger pistons, rods and performance cams but where do you stop. Check your clutch plates whilst you have it apart and check all your hoses in case they need replacing.:)
Personally I would just fit the helicoil and ride the bike, buy a cheap engine to strip down and rebuild over time while you are riding that way you get to learn about the engine/gearbox at your leisure without cutting into your riding time then it's a matter of swapping over the engine when it suits you and if you don't have a workshop manual get one as it is cheap insurance in making sure all things are what they should be.;)
 

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Discussion Starter #7
Well it was using a food bit of oil. Was not ready to undertake that quite yet but here we go.

I don't know enough to trust a helicoil. I don't want to do this twice.

I took of the htev valve and servo and it started running a little rich, black smoke, had to clear it out from time to time. I pulled the power commander just before this happened so i didn't get to see if it cleared up.

Think the helicoil will hold?
 

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The helicoil is a brilliant repair and done right it is a permanent fix, I have done dozens of helicoils years ago in early vee dubs as fitting the wrong brand of spark plug meant pulling the thread with the plug.
The black smoke that you mention is an over rich mixture if it was the rings worn it would be a light blue smoke for burning oil and also an over rich mixture will cause excessive oil usage due to fuel washing down the oil on the cylinder walls as well as possibly diluting the oil.:)
 

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Discussion Starter #9
I gotcha. Bike is just over 39,000 miles and was running strong until this.

Do you recommend drilling the whole then a helicoil? What will the helicoil grip to in a smooth bore? Tap it? Size recommendations if you know off hand?
 

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I gotcha. Bike is just over 39,000 miles and was running strong until this.

Do you recommend drilling the whole then a helicoil? What will the helicoil grip to in a smooth bore? Tap it? Size recommendations if you know off hand?
You do need to drill and tap the head for the helicoil to screw to just take your spark plug to where you buy the helicoil and they will size it up for you, it has done a few miles but if it's been serviced regularly and it was running fine before it should be okay with just a helicoil.;)
 

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helicoil has threads on the inside(the size of the spark plug) and on the outside. you basically drill the original hole out n tap the hole a couple sizes bigger. the helicoil screws into that n the spark plug screws into the helicoil. since they are made of steal the threads hold up better than the aluminum block so i think its a better than original fix really. its important to keep your bit at a 90 degree angle n i think its best to start with a smaller bit n move up a size at a time. you really dont hafta drill much past the original threads tho. again when you tap it, take your time n use an aluminum cutting fluid to keep from getting the tap stuck. obviously your probably going to need to take the head off because your going to get shavings all down the hole n that would be pretty bad for the engine! everything you need really isnt all that expensive. much cheaper than a new head n is a solid fix. if your not comfortable drilling it out n stuff just find a reputable shop to do it. just not the epoxy the plug in guy! lol probably wouldnt be much once the head is off the engine.
 

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Discussion Starter #13
10 4

Leaves me questioning what to do about the rings. Will I need to have the jug honed out for new rings? I had to put a few ounces of oil in it every ride leading up to this BUT it didn't smoking perfucely. A little puff of white smoke maybe every ten minutes and I would just open it up and it would clear out.

Anything else I should expect to break down on this thing in the near future?
 

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Sounds like you may need to do rings but the cylinders have a coating so it is not a simple bore and hone of the cylinders as you will need to have the coating put back on the bores. I think if you do a search on this forum you will find plenty of info regarding the bores. :)
 

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Sounds like you may need to do rings but the cylinders have a coating so it is not a simple bore and hone of the cylinders as you will need to have the coating put back on the bores. I think if you do a search on this forum you will find plenty of info regarding the bores. :)
It isn't a coating. And probably the bores would need some attention but if it's working i wouldn't bother. Alusil can be bored and honed to 0.25 mm oversize. But the impression i got is that it would need special equipment.
 

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It isn't a coating. And probably the bores would need some attention but if it's working i wouldn't bother. Alusil can be bored and honed to 0.25 mm oversize. But the impression i got is that it would need special equipment.
Thanks for the info Mika I wasn't sure of what the bores were but I did know they were not straight iron bores/sleeves.;)
 
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