Cylinder Head Coolant Joint

[twigg]

I need to remove one of the coolant joints in the cylinder head, because it is leaking and the O-rings have to be replaced.

 

The joint is held in by a spring pin, and access is very tight.

 

The part itself is plastic and doesn't seem to want to move.

 

Before I resort to breaking this part out, with all the risk that entails, does anyone have a method of removing this that has worked for them?

 

Thanks.

[dingy]

I have removed these a few times. Sometimes you can save them sometimes not. The plastic gets brittle.

 

They always seem to break apart if a pair of pliers is used to try to remove them using the tabs on the exposed end.

 

If motor is out of bike this may help. If motor is in bike, good luck and post if you find a way to get it out.

 

In the top of the head there are 3 water jacket plugs. One of these is over the bypass joint. If you remove that plug, you will be able to see the plastic joint. There will be a hole in the top of this joint right under the plug that was removed, about 1/4" dia. I put the tips of a set of needle nose pliers in this hole and lightly pry against the block. Sometimes this will push the joint out intact.

Added a picture of head. The plug laying on head is over hole that will expose bypass joint. Other two plugs are located outboard of the spark plug holes.

 

Gary

Edited April 13, 2011 by dingy
added picture

[twigg]

That was just the kind of info that might help .... Off to try it before I order a new joint.

[twigg]

That was just the kind of info that might help .... Off to try it before I order a new joint.

 

Blech!

 

New joint ordered!!

 

When I tried to ease the joint out using that hole, the hole got bigger and the joint fell apart. I got it all out, well the front half. The back section is intact, but still in the head.

 

I will get a large screw, or maybe use a tap to screw into what is left and pull it out.

 

On a brighter note, the carb diaphrams arrived in under two weeks.

 

They fitted onto the slides perfectly, so when I refit the exhaust we can see how much difference they have made.

[twigg]

To anyone who was following this saga ....

 

The joint refused to budge and the front half broke apart when I tried to lever it through the water jacket plug hole above the joint.

 

In the end, the two thirds that remained buried deep in the engine came out cleanly, in about ten seconds, like this:

 

http://i1092.photobucket.com/albums/i418/twigg2324/1986%20Yamaha%20Venture%20Royale/IMG_0516.jpg

 

So we are back on track

[BradT]

Nice, so there is an easy method after you break it.

 

Glad that is all that happened.

 

Brad

[twigg]

Nice, so there is an easy method after you break it.

 

Glad that is all that happened.

 

Brad

 

I don't think any fell into the engine or cooling system, but it's soft, crumbly plastic, so there will be little harm done if it did.