Removing the cylinders

[JWSanders]

The last week or so I've been dismantling the engine on my parts bike, to get it ready for the summer long job of polishing, and such. I've ran into a problem though. I for the life of me can't get the cylinder jugs off the motor. They appear to be stuck fast.

I've pried at the pry points on the front (with a big scewdriver, afraid to use anything bigger), savagely beat it with a rubber mallet, and even hoisted the whole engine up by the jugs and beat it some more with the mallet. No dice.

Been searching for the last couple of days and only found one post about removing a stuck cylinder block. Wasn't much help. Anyone have any ideas about what else might work?

[John]

Do you have the cases split? I don't remember, but can't you get to the rods when the engine is split? Does it still turn over? Maybe you could remove the rod caps, and lift the cylinders and rods off the crank, and then you could beat them out with a 2x4 or similar.

[Ken Talbot]

Have a look at this photo of a cylinder block just after it has lifted free of the crankcase:

You'll notice a lot of cr@p built up around the bottom of the studs, especially the ones on the front side. Over time, a lot of road grit blasts onto the unprotected shaft of the studs, it mixes with a bit oil dripping down the studs, then engine heat fuses the whole works into a nasty, solid plug. Get lots of penetrating oil in there, and use some fine dental picks to pick out the fused plugs. Do this on all oif the studs, than go back to work with your rubber mallet to knock the cylinder block free. Be real careful of prying...

[JWSanders]

I havent split the cases yet. Was hoping to wait to have to take the bottom end apart so as not to fill what little space I have left in my storage room with motor innards. (And I will soon have a new addition, an XS400! ) Will be a while before I have the top end shiney and new again. Was going to leave the bottom intact until I was ready to polish those cases. The motor spins freely. Head, cams and all that came off with no problem at all. This is my first attempt at dismantling the 1100's engine, so I'm not sure what all it entails.


Thanks for the hint Ken, I'll get some better penetrating oil and let those soak for a day or so. I'm really looking forward to getting this process started. My bike will look brand new by the end of summer come hell or high water!!

[xj11john]

End of the summer?

JW,

I guess that means we won't be able to ride our beasts this summer

Unless that 400 is up to it ? Well I'll be busy too, I'm currently just started playing (drums) for another band

So I'll be busy as well, but I'm still going to ride when ever I can, between work, and band playing

Is'nt life great Well good luck and God's speed with your project on the 11.

Keep us posted as I know you will, and pics if you can,
Later,

[prometheus578]

"Oh, you're such a stud!"

Ken's right about the sand and grit around the studs, but that's not really what's holding it down.(In my opinion) The grit and $hit causes probs when trying to remove the cylinder from the engine... the grit fills the channels that the studs slide into. Not really a problem sliding the cylinder up, till... it gets to the point where the studs flair where the threads are. Then the grit filled channels, which have formed to the diameter of the studs.. hang up and can't slide past the flaired ends.
As far as initially separating the cylinder from the case... HAHAHAHA have fun! Took me three hours one time! (lost money on that job!) Finally ground down some chisels, and managed to tap them between the cylinder and the base and eventually to lift it up and break the gasket. The gasket bonds to the case and also to the cylinder.
The effort here is expended in trying to have the gasket rip in half thickness-wise, if you know what I mean. You'll end up with the top half of the gasket bonded on the cylinder, and the bottom half bonded on the case.
Use JBWeld to glue back on the fins that you break off!
I'm not trying to make light of your situation... just stating that it's a real joy of a job.

[JWSanders]

Hey John....luckily, my 11 is still together and running, but I will probably start dismantling it again before long. I am hoping that the 400 I'm picking up (tonight ) will carry me riding throughout the summer. It's like a little baby version of the 11..same color, look and everythng. It's an 81 Heritage Special. I need a smaller bike to get more experience on, and it will be perfect for my son when he reaches licenseable age (which is only a couple of short years away).


Pro...I sure hope it dosen't come to that. I really hope I don't break any fins. Hopefully a few days soaking in penetrating oil will help some. I can see how it can be a bugger though...it's on there well.

[prometheus578]

"Wish in one hand... and *** in the other..."

I sure hope it dosen't come to that.

Nor do I. Some just pop right off. Others will make you question your sanity.

[John]

Stupid Question Time

You do have the cams, and the tensioner removed, right?

[andreashweiss]

Once the head if off and cam chain has fallen into lower engine case you will be attempting to pull off the cylinder jugs. I usually use a propane torch to heat the cylinder bolts (heat applied to lower engine case) ONCE THESE ARE REMOVED. Gently pry with equal pressure in several spots until you physical see the jugs move from there just a matter of slowly forcing cylinder jugs up slowly. By pulling up with your hands. Nothing is holding the jugs on to the lower engine case. MOST times the resistence is the cylinder head bolts. Remove them. Andreas

[JWSanders]

Yeah, head's off. It came off easy.

I've got the cylinders soaking in penetrating oil now. Will let it soak for a few days while I get this little 400 up to speed. Hopefully it will be more receptive to my pulling then. I'll try the torch if that doesn't work. Thanks for all the advice!!


One thing's for sure, the little buckhorn bars on the 400's gotta go. I only thought the ones on the XS11 were weird feeling. These are a good 6 inches narrower. Kinda like driving a 2-wheeled tiller. It seems to be a pretty zippy bike for it's size though. Putted it around for about 15 minutes today. Once I get it tuned up a little better it should be a fun bike.