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#142440 - 08/06/18 02:02 PM Re: Exhaust bolt broken in head\cam stuck [Re: Rocky Baker]
Paul49 Offline
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Registered: 07/22/11
Posts: 1594
Loc: High Peak, UK
Brilliant, that sounds like a very fine bit of TIG welding by a very skilled operator.

I was considering fitting copper greased steel studs with brass nuts but I'll wait until the exhaust needs to come off for a very good reason.
_________________________
1958 Ariel 650 FH, 2014 Tiger Sport1050, 1995 XT225 Serow, Tiger 800 XRx.

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#142441 - 08/06/18 02:36 PM Re: Exhaust bolt broken in head\cam stuck [Re: Rocky Baker]
peejman Offline
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Registered: 06/03/13
Posts: 2844
Loc: East TN USA
We've had to do that on occasion for aircraft parts. Sometimes just hitting the stud with the arc will cause it to shrink enough to break loose. I hadn't thought about a machinist doing the welding as they're separate jobs here. Good work for sure.
_________________________
This shall pass, be still and know.
2006 XT225, UNI filter, ProTaper bars, MSR handguards, SS front brake line, Shinko 241's.

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#142495 - 08/10/18 03:45 AM Re: Exhaust bolt broken in head\cam stuck [Re: Muniac]
Rocky Baker Offline
Junior Member

Registered: 05/10/18
Posts: 18
Loc: ON
Thanks Muniac for taking care of this site and thanks Shawn C for the step by step timing chain disassembly guide.

You are a life saver!

I just finished rebuilding my 1992 Xt225 and the darn thing just would start. I would turn over, it had compression, spark, gas, air....and the thing just would just get a slight sputter sometimes. Considering the year and te rough condition of the bike, I started thinking the purchase of the bike and the time and money put into rebuilding it was a total waste. The fact that it sputtered sometimes kept me going so I was thinking maybe it was a timing issue.

So I drained the oil and reopened the alternator cover. Not being a mechanic, I used your step by step guide to get to the bottom timing chain sprocket and there it was! The chain wasn't even on the sprocket! I then reinstalled everything like you wrote making sure all the timing notches were lined up. Closed everything up, threw some new oil in there and she started right up!!

I have litterally spent most of my spare time all summer working on this bike and your write up helped make it all worth it. Big thanks from this guy who now has a street legal Serow with a newly rebuilt engine and carb for a total of 850$ CAD. I'd say that's a pretty good bargain. Tomorow is break-in time!! &#127949;&#128515;&#128515;
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Keep it simple

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#142496 - 08/10/18 12:08 PM Re: Exhaust bolt broken in head\cam stuck [Re: Rocky Baker]
peejman Offline
Platinum Member
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Registered: 06/03/13
Posts: 2844
Loc: East TN USA
Glad you got it fixed, and you're really lucky. The valves must have been closed when you put the head back together. If they'd been open, the piston would have whacked and bent them when you tried to start it.

Next time, rotate the engine by hand with the valve covers off and verify everything is moving like it should before trying to start it.

Did you confirm oil flow to the head via the bleed bolt?
_________________________
This shall pass, be still and know.
2006 XT225, UNI filter, ProTaper bars, MSR handguards, SS front brake line, Shinko 241's.

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#142501 - 08/10/18 03:28 PM Re: Exhaust bolt broken in head\cam stuck [Re: Rocky Baker]
Muniac Offline


Platinum Member
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Registered: 01/16/04
Posts: 5433
Loc: Montrose, CO
Always glad to hear the site is helping riders out with repairs. My thanks to those taking the time to contribute valuable content here for others to benefit from. As they say in this business, "Content is king!" Enjoy your bike and ride safely.
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Evolve & Simplify
Be There or Be Nowhere! A Few Adventures & Video

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#142508 - 08/11/18 02:11 AM Re: Exhaust bolt broken in head\cam stuck [Re: peejman]
Rocky Baker Offline
Junior Member

Registered: 05/10/18
Posts: 18
Loc: ON
I did and the pressure must be good because I'm still cleaning some of the oil that spewed out haha. Thanks for the advice on the head. I will definitely be doing that next time, if there is a next time with this bike haha. How long does a new top end last if I'm not a crazy rider and do regular oil changes?
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Keep it simple

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#142509 - 08/11/18 02:15 AM Re: Exhaust bolt broken in head\cam stuck [Re: Muniac]
Rocky Baker Offline
Junior Member

Registered: 05/10/18
Posts: 18
Loc: ON
Now that I have the bike functioning properly, I do plan on slowly adding little things here and there. Everything different I do, I plan on posting here for sure, mostly concentrating on really low budget DIY type of things. I Bought some hardware recently which I believe should help me make a decent windscreen for about 20$. That will be the first thing a contribute but I hope there is much more to come haha
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Keep it simple

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#142514 - 08/11/18 03:53 PM Re: Exhaust bolt broken in head\cam stuck [Re: Rocky Baker]
Muniac Offline


Platinum Member
*****

Registered: 01/16/04
Posts: 5433
Loc: Montrose, CO
Thanks in advance for any project contributions you'll make. Enjoy your bike and be safe.
_________________________
Evolve & Simplify
Be There or Be Nowhere! A Few Adventures & Video

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