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General Category >> Rubber Side Down! >> Help Please in removing my head.
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Message started by Trippah on 06/04/08 at 11:41:24

Title: Help Please in removing my head.
Post by Trippah on 06/04/08 at 11:41:24

Well, none of the shops in my area will work on the savage until Fall, so like a fool I've started wrecking it myself. The diagram of the cylinder head cover bolts was duly printed out and attached to cardboard as recommended (what a great idea, thanks). The 10mm bolts all came out but on the left hand side, the chart shows one more bolt but I have 2X 14mm bolts, one near the spark plug hole, one further back. Did I misread the chart? (Awaiting response before trying to remove the 14mm. ) idn't touch the 10mm on the right side with the philip heads indentation- hopefully that was the one I wasn't supposed to touch yet. Do I have to remove the front L65 with nut?
The right hand side crankcase cover came off with a little spillage of oil- didn't put the bucket in the right spot by (as agent Smart would say)- missed it by that much. :) When cleaning up the oil I found a very thin @3mm thick metal pin that is broken off , maybee 1/2 inch long. Any thoughts what it is/where it might have come from. The bike is an '04 with 3000 miles. Thank you in advance..
OH, yeah, this is being done so I can get a header bolt machined out. :(

Title: Re: Help Please in removing my head.
Post by Sandy Koocanusa on 06/04/08 at 11:51:24

Sorry I can't help, but the title of your thread made me smile. I was going to suggest riding without your helmet, until I read of your woes. Good luck on your project.

Title: Re: Help Please in removing my head.
Post by verslagen1 on 06/04/08 at 11:59:09

Trip, leave the 14mm til later. They bolt the head to the cylinder.
Concentrate of the 10mm first, get the cover off, then do the 14's.

The pin might be an alignment pin for the cover, there are 2, one front and one back. Look for a couple of blind holes.

Title: Re: Help Please in removing my head.
Post by Max_Morley on 06/04/08 at 12:45:59

Lets go back to square 1, are you trying to remove just the head cover or it and the head? To remove the head cover, only 6 mm bolts with a 10 mm hex need to be removed. Don't forget the 2 under the valve adjusting covers, and yes the inverted one with the acorn nut has to be removed also, nut only until you slide the cover sideways to allow the bolt to drop out. Also the head steady rest has to be removed, 3x 12 mm boltsw/14 mm hex, that go through the frame top tube. Also the center bolt stay in the cover until you remove it and goes back in the cover before you pt it in place. Pin might go in your cam to gear, side cover ones are hollow dowel type alignment pins. What happened that you are taking it apart? Max

Title: Re: Help Please in removing my head.
Post by Trippah on 06/04/08 at 14:39:29

First, thanks for the replies. I snapped an exhaust header bolt, then the easy out..so, I now need to take the "cylinder head " (I think its called) off so a machine shop can remove the ofending bolt etc. (If it sounds like I'm new at this. the answer is yes) :o

As far as(part of a pin)? I fond, it is solid not hollow dowel type. The pin in cam gear doesn't sound very promising..

The cover comes off seperately? Those 2 14mm bolts look like they hold the cover to the head.

Max- you say the center bolt stays in the cover, this is the one that has the philips' head indentation?

So..worst case senario- how much can I get parting the poor baby out?? Naw..at 62, it's time to learn new stuff- right?

Title: Re: Help Please in removing my head.
Post by verslagen1 on 06/04/08 at 15:05:57

Cover comes off sepparately.
If fact you have to take it off 1st to get at the bolt under the imfamous head plug.
The one that stays in is marked with an indentation of some sort. It retains the rocker shaft, not a problem if it's removed, just put it back in before replacing the cover.
Don't tempt me. ;D

Title: Re: Help Please in removing my head.
Post by Trippah on 06/04/08 at 15:21:16

So, all the 10 mm bolts are out, do I whack the head cover with rubber mallet or is this a pry with screwdriver kinda operation?

Title: Re: Help Please in removing my head.
Post by verslagen1 on 06/04/08 at 16:54:42

you'll have to pry a little, it is glued down. I think there's a space at the rear but don't recall exactly.

Title: Re: Help Please in removing my head.
Post by Trippah on 06/04/08 at 20:05:43

Thanks for the help Verslagen1. Will try prying tomorrow am before work. Have a great evening.

Title: Re: Help Please in removing my head.
Post by meck on 06/05/08 at 05:14:22

Trippah, I did notice when I did the same things that some of the holes in the diagram are the bolts from the two chrome covers that you may have already removed. So don't necessarily think you missed something.

As for getting the head off, that took me about 10 minutes of wriggling and twisting and biting my tongue just so... Depending on the tolerances of your frame and the mounting bolts in the cylinder, you have to get the thing in just the right configuration to remove it.

I just got in my new gaskets and head plug, so I'm going to be doing my reassembly tomorrow afternoon into the weekend. I'll keep you updated over in the "broken header stud" thread for anything that might be handy during your reassembly. I know you said you are in the Worcester area... I might be able to ride up sometime in the next couple weeks if you would like another inexperienced hand. :)

Title: Re: Help Please in removing my head.
Post by drharveys on 06/05/08 at 09:16:54

Whatever you do, don't follow this guy's head removal technique:

http://i40.photobucket.com/albums/e204/drharveys/Tudors.jpg

He was pretty good at getting the heads off, but things never worked right afterwards!

Title: Re: Help Please in removing my head.
Post by Trippah on 06/05/08 at 15:51:22

Hope it goes smoothly Meck - I may well be contacting you (perhaps we can get you friend to do some work on another savage now that he has experienced it :D (But I get ahead of myself)..tried a screw driver prying around but as yet no movement noted.
As far as the tudors ..especially the tv variety, if a gal has legs like hers, who'd even notice whether she has a head :o

Title: Re: Help Please in removing my head.
Post by verslagen1 on 06/05/08 at 17:01:03

Check around for more bolts, did you get the 2 under the valve covers?

Title: Re: Help Please in removing my head.
Post by Trippah on 06/05/08 at 19:27:10

Verslagen- i got those BUT, there is one directly under the frame member tucked in- that I had previously missed. >:( I So, how dumb do I feel! I Can't get a socket on it so it must be time to drop the engine.
This hapened cause I was working with the engine still in place, i was hoping this would make it steadier. Thus I was coming in from the sides which meant the frame member was blocking my view a little. Alas, my garage which isn't all that well lit. Finally got some candle power and voila. I guess I'll have to lower the engine now, to get this last 10mm bolt out.
Have you ever seen my greenhouse, it's called The Sahara. :D

Title: Re: Help Please in removing my head.
Post by verslagen1 on 06/05/08 at 20:14:31

You might try backing it out with an open wrench.

But with it so tight, it might be best to yank it out.

Other option, take out all the engine mt. bolts and rock it forward for a little more clearance, Clarence.

;D

Title: Re: Help Please in removing my head.
Post by Trippah on 06/05/08 at 20:21:22

Thanks for the suggestion- would I have to disconnect the drive belt as well? It's gonna be 90 degrees this weekend, this will help me work up a sweat for sure. ;)

Title: Re: Help Please in removing my head.
Post by verslagen1 on 06/05/08 at 21:02:43

I didn't.

Only 80 today, c'mon over.

;D