Exhaust Studs

[darrsi]

Yup, that'll be them....

[Dead Eye]

Yeah, the damn things are prone to snapping and rusting quite a lot if they aren't looked after. Unfortunately this is exactly my issue.

The old pipes need to be welded quite a bit to be able to pass an M.O.T. regardless and I doubt they would have been suitable for this (metal is too thin now) so they had to come off sooner or later and with the state of the nuts and studs its no surprise they snapped, its just a pain in the ass. The first two came out without too much of a fight, but the subsequent 6 required probably half the amount of torque and just snapped clean off. I guess the metal had just been fatigued too much.

I'm trying what I can to get the bike fixed as fast as possible, but I have no undercover work space (since the garage hasn't been rebuilt yet) and the weather plus a heavy work load is not helping either. If I get extremely lucky and my boss decides that he loves me (not in that way you dirty foccers  :lol ) then I may be able to start, and potentially complete, the engine removal tomorrow / Friday. Then I just need to get the old studs out and get the engine back in...

[kebab19]

You could get maybe another decent cylinder head off ebay to keep the time spent off road to a minimum?

Stud removal can be a real boll1x. With 3 studs snapped off, I had to take one of my heads to a local engineering shop - I dunno what process they used but got 'em out in a day(!) Don't think I'd have ever got them out myself without ruining the head.

[Dead Eye]

Well my bike isn't my main form of transport thankfully and I work from home, plus the supermarkets delivery so I should be ok with it off the road  :lol

I've begun work today in removing the engine and I've just finished getting the carbs out, so time to move on to the next step. If I'm lucky I might be able to finish getting the engine out today, get it to a machine shop tomorrow then reassemble on Saturday? Granted that is quite an optimistic time frame

[Dead Eye]

Right, I am at the stage of removing the engine but im stuck

Can anyone tell me what size this nut is. It is behind the oil filter at the front of the engine - I've removed the filter already obviously but the stud is hitting the frame just enough to prevent the engine from coming out.

[born to be mild]

I would think that its just a spigot for the filter to screw on to, it should ha-ha just undo, you know, just like the exhaust nuts do. The safest bet is to get a parts diagram if Haynes doesnt cover it but I doubt its anything other than a male/male reducer bolted in at the factory probably after the engine is in the frame, the fact that its got a hex on it makes it look like it comes out, but then your entire bike has a hex on it at the moment !
I hope it works out for you, youve more patience than I have in this weather.

[Dead Eye]

I thought to check the Haynes after I posted and managed to find that it was 30mm nut and that it allowed the removal of the oil cooler which is the unit behind the oil filter. So after an hour in rush hour traffic to get a 30mm socket, I got back to the pitch black garden and managed to finally get the engine out. Not bad for a days work I think and I'm on schedule. If it wasn't for the meet on Sunday (which I'm trying my fiercest to get to) then I would do a lot more work and maintenance on the engine whilst its out of the frame.

The weather hasn't been overly bad, quite wet on the ground this morning but it remained dry all day but with very strong gusts of wind - damn oil and coolant has gone everywhere because of it

So, does anyone know any machine shops in Chelmsford how are cheap and have a quick turn around

[packie]

I thought to check the Haynes after I posted and managed to find that it was 30mm nut and that it allowed the removal of the oil cooler which is the unit behind the oil filter. So after an hour in rush hour traffic to get a 30mm socket, I got back to the pitch black garden and managed to finally get the engine out. Not bad for a days work I think and I'm on schedule. If it wasn't for the meet on Sunday (which I'm trying my fiercest to get to) then I would do a lot more work and maintenance on the engine whilst its out of the frame.

The weather hasn't been overly bad, quite wet on the ground this morning but it remained dry all day but with very strong gusts of wind - damn oil and coolant has gone everywhere because of it

So, does anyone know any machine shops in Chelmsford how are cheap and have a quick turn around

There will be other meet-ups and rides, so missing one won't kill you. You might not have the will to pull the engine out and go through all that again later for maintenance work. Concentrate on getting the maintenance work that you need to do sorted, and get the engine right before putting it back in. You could even tidy it up and give it a DIY spray it to jazz it up a bit as well. You'd be more happier at all the other meets for doing so down the road.

[reillypadraig]

I think it might be a 22, can't remember now, been awhile since I put my engine in, how far u on with it?

[Dead Eye]

@packie: Yeah I know, its something I had considered and the events of today will force my hand one way or the other - if I can't get the studs removed then there is no way I can get the bike ready in time regardless. But I'm young and love mechanics. Doing all the work yesterday was actually fun for me, the back ache etc not so much, but still

@reilly: See my previous post above It was a 30mm nut and the engine is out and ready to be loaded in to my cage, which I am about to go and do

[packie]

@reilly: See my previous post above It was a 30mm nut and the engine is out and ready to be loaded in to my cage, which I am about to go and do

You must be built like Arnie....that a big lump to be....err....lumping!! :eek

[Dead Eye]

I wish I was built like arnie! But I did manage it thankfully. I've just got back from an engineering place who basically said they can't do it in its current state and they would need to have the head removed. They also quoted around £120 for the job and a turn around of about a week... so that wasn't particularly good news.

Probably going to just wait for my impact stud extractor to arrive (damn post) and see how many of them I can get out without snapping. Fingers crossed that I then only need one to be removed and I can find somewhere else that will do it with the head still attached. Needless to say, its likely that the bike will definitely not be ready for Sunday...

[red98]

thats a shame about sunday matey,nobody can say you have not tryed,well done in getting this far    that quote sounds a bit high to me might be worth shopping round.......removing the head is straight forward . no special tools needed but you will need a new head gasket 

[Dead Eye]

Well if I can get more of the studs out successfully it should drop the quote - he was quoting for removing 7 studs to be fair

Update: I've been out in the garden hammering away with my impact driver and successfully removed 5 of the offending studs. 1 more however decided to snap off flush with the head but at least there are only 2 studs to deal with, instead of 7

Going to give one more machine shop a quick ring and see what they say

Update 2: Right, I've dropped off the engine with this other company who seemed much more helpful and said that it should be around £25 which is much more acceptable Mind you, my thumb is certainly hurting after hitting with the hammer several times  :wall

[GrahamB]

Result! I took my FZ engine to my mate who has his own engineering shop but we didn't use anything more than a hand drill with me holding the entire engine so he could give it some welly with the drill. Otherwise he would have wanted the head off to get it on his pillar drill & I've only just fitted it with new gasket & 20 new shims! Cost me £4.50 for his cooked breakfast. Well worth it. I couldn't drill it with engine in frame.
Really pleased for you.  Don't do your new nuts up too tight when it's all back together! lol

[Dead Eye]

Haha, yeah I will be applying some copper grease I think and periodically removing them and cleaning them up to prevent it from happening again. Hopefully give the engine a damn good clean whilst its out of the frame as well. I think the previous owners just kept it in running order but never bothered to wash the poor thing.

[GrahamB]

Just the nuts. Don't be removing exhaust studs unless you really really got to!

[Dead Eye]

A fair enough point as the studs only needed to be removed because they snapped and they only snapped because the damn nuts wouldn't come off

[swem]

hi  i think its either a 30 or a 32  a socket works best  :rolleyes   

[packie]

A fair enough point as the studs only needed to be removed because they snapped and they only snapped because the damn nuts wouldn't come off

Why would anyone want their nuts to come off?  :moon