Cylinders are stuck (really stuck)

[RichV]

I'm trying to get the jugs off this previously seized engine and it's killing me.

I've searched the site (and the net) and have found numerous solutions but none have worked so far. I came up with my own "solution" using four nuts, two flat iron parts with holes for two bolts each, a wood 1x4 for structure, about a foot of angle iron, and two clamps.

I pushed down on the four center rods while using the clamps to pull up the cylinders. I used a vice grip on the clamp to get them real tight to the point that they are starting to travel a bit (dangerous).

Here's a photo.



It's been sitting now for 24 hours without any movement. Any suggestions?

I've thought of replacing the clamps with bolts going through the front and back holes but I worry that the bolts will be too thin for the task and will snap.

Thanks again for all the great advice.

[trbig]

Not sure how you haven't snapped off that little aluminum piece in the rear of the motor yet that the clamp is attached to.

You said you'd read some things, but did you see this? http://xs11.com/forum/showthread.php?t=35427

Down inside the cam chain galley is the only place I see with enough material to really put some pressure on. But, if you've got one side loose, sometimes you can work something into that crack on the front and back sides, then using that as a fulcrum point, hitting the raised side will usually raise the other side. Some people use a small piece of wire such as a guitar string and saw through the base gasket to loosen it up.

All this is for normal instances though. If you've got a piston that's welded to a cylinder wall, it'd be better to destroy just that one cylinder/piston than it would a whole set of cylinders.

[natemoen]

Yeah, I too don't know how you havemt snapped that tab off. People break that thing off with way less stress than you are putting on it!

[RichV]

I saw the tool before but I don't have the ability to fabricate it.

Although it looks like I have a lot of pressure on the tab, I really don't. Anyway, I will remove it.

I don't have welding equipment so I can't make anything like suggested. I'll have to think about it some more I guess.

[bikerphil]

There are fulcrum points for prying near each of the front two motor mounts. You can try using a pry bar in those areas and soak down the stud holes with PB Blaster. You cab also tap a putty knife in where the base gasket is and then maybe a small screwdriver.

[mack]

seized pistons

I had to pull the cases apart and remove the piston rods from the crank. The the jugs came up ok but two of the pistons were rust welded to the sleeves. Took 5.5 ton to break them free. If yours are the same as mine, you'll never pull those jugs free of the pistons. You may have to split the cases like I did.

[RichV]

I was able to get the pistons moving again so they are not the problem. It won't even give me a gap to work with.

On another site, someone had to soak it in oil for a month. I did try WD40 and nothing moved. I beat it with a rubber mallet with no luck.

It's like it's welded on there. Two of the posts have sleeves on then that "may" have expanded locking them in place. WD40 will not penetrate.

[motoman]

I was able to get the pistons moving again so they are not the problem. It won't even give me a gap to work with.

On another site, someone had to soak it in oil for a month. I did try WD40 and nothing moved. I beat it with a rubber mallet with no luck.

It's like it's welded on there. Two of the posts have sleeves on then that "may" have expanded locking them in place. WD40 will not penetrate.

Kroil may give ya some hope..

[James England]

I don't want to put a downer on you but once, using an engine from a totally beyond all help parts bike, I tried,just for the hell of it, to get the barrels off the engine. Now, before any expressions of shock and disgust from anyone, this bike was in terrible condition. Fins broken off all over the engine etc. A total wreck.

I tried everything to get the barrels off and finally got a 5lb sledge hammer and whacked them repeatedly. They still did not come off. I tried levers in the pry points and would not advise using them..all that happened was that they got chewed up.

I gave up.


The only thing I'm wondering is maybe the careful use of heat? That's the only thing I didn't try

[James England]

Just been thinking about my recent XJR exhaust stud from hell. One of the eight would not come out. What eventually got the stud to move was the use of a welder. I welded a bolt onto it and the heat from the welding loosened the stud.

So....if you get desperate, why not remove any of the barrel bolts that you can and, for the seized ones, weld something...anything..onto them. The heat may free up the sleeves, allowing the bolts to come out. I would have thought that barrels on the cases but no bolts or sleeves might just make the barrels easier to get off.

[RichV]

I tried using a heat gun to free it up. No good.

For a while there I was thinking I could make the engine work. Loosing hope as time goes along.

[James England]

I tried using a heat gun to free it up. No good.

For a while there I was thinking I could make the engine work. Loosing hope as time goes along.

It's not hot enough, I'd say. Weld the seized studs and get them out.......

[DGXSER]

First word of advice, toss the WD-40 if your goal is to loosen a stuck part. It is all but useless at this. Get the PB Blaster or Liquid Wrench. It is a thousand times more effective.

I only did this once, and it was on a good condition well taken care of engine, so it was not horribly difficult. For you, since you do not weld (I don't either) I would take a piece of thick angle iron. like this...



Cut it down so it can drop into the tunnel and then be turned so the leg goes into the spot Tod put his hook. Now, run the all thread through the bottom hole put a nut and washer on it, then drill through the side plate hole through the all thread and use a tight fitting bolt through both to lock it at the 90 degree angle, and to keep it from spinning. Not something I have tried, just an idea of how you might improvise a similar tool.

[D0wn5h1ft]

If it were me? I would get some liquid wrench, soak it for 24 hours, and then get myself a rubber mallet, cover the fins in a old towel and start beating the S**T out of it until the jugs came free.

If the pistons aren't stuck it should get free but you might have to get nasty with it.

CAUTION: Everything above is last resort material.

[D0wn5h1ft]

If it were me? I would get some liquid wrench, soak it for 24 hours, and then get myself a rubber mallet, cover the fins in a old towel and start beating the S**T out of it until the jugs came free. I was taught the four S's: soak, shake, strike, and shout.

If the pistons aren't stuck it should get free but you might have to get nasty with it.

CAUTION: Everything above is last resort material.