If I could only kick myself!

[Nubian]

Broke an exhaust stud, the inside one from #4. Looks like I may have to drop engine to try to repair it, as the frame is in the way and I can't find any elongated left turn drill bits or extractors that can reach it past the frame tube.







If that is indeed the case, I might as well do a complete rebuild and address a host of other issues like 2nd gear, electric clutch, checking and most likely replacing cam chain, valves etc.....

Meanwhile, I started the motor and there is no leak that I can tell coming from the broken side. With the non-broken end secured in place can I get away with still riding it for a while or will the vibration brake the other side off?

[James England]

A thought.... couldn't you undo the engine mountings and move the engine in the frame, just enough to get a drill bit in there?

[BA80]

It's always the toughest one to get to that breaks ain't it.

Check with the tool trucks. Snap On, Matco and such. They have stuff you can't get elswhere.

90º drills are available at places like Harbor Freight also.

[Nubian]

A thought.... couldn't you undo the engine mountings and move the engine in the frame, just enough to get a drill bit in there?

Never thought of that, will see

[GLoweVA]

You don't have to pull the whole engine, just the head. taking the head off isn't that more difficult than taking off the valve cover and cams out.
then it's just 14 nuts and the oil tube. Make sure you attach a bungee cord to the cam chain to keep it from falling into the engine.

then with the head out, you can drill out that stud and fit in a new one.
I've had my head off and replaced a valve all in less than one day.

[Nubian]

You don't have to pull the whole engine, just the head. taking the head off isn't that more difficult than taking off the valve cover and cams out.
then it's just 14 nuts and the oil tube. Make sure you attach a bungee cord to the cam chain to keep it from falling into the engine.

then with the head out, you can drill out that stud and fit in a new one.
I've had my head off and replaced a valve all in less than one day.

I can pull the head off w/o pulling engine? I did not think there was enough clearance there.

How about me wanting to still ride it as is for awhile.

[GLoweVA]

Yeah you can pull the head off the engine while it's on the bike.
You've got to pull the cams of course, and I've found that pulling the ballast resistor off helps get a bit more clearance, but If you've got an 81, then I don't think you have a ballast resistor under the frame rail there anyway.

If you're careful about it, you can even reuse the head gasket. It likes to hang up on the front and rear underside studs. Those are the 2 nuts that are bottom part of the head, center. the front one is just above the cam tensioner and the rear one is just below the oil pipe.

you can probably ride it for a while with just the one header nut, but I'd check it often to make sure it doesn't work loose. Losing both and having nothing holding that pipe on it could come loose and fall off.
Sound is going to be your biggest clue as to what it's doing.
I lost a nut a while back and when I got to a stop light, I could hear a difference as it was leaking some. Got home and used a spare one off my SG until I got on in the mail.

[trbig]

If there's an exhaust leak, the hot gasses can easily cut through the aluminum head material. So.. if you've got a replacement head and don't mind junking that one, ride away.