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techtalk:evo:engmech03a [2019/08/04 14:18] – [Using a pipe wrench to loosen the stud] hippysmacktechtalk:evo:engmech03a [2024/01/03 20:54] (current) – hippysmack
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 ====== Cylinder / Head Bolt Issues and Repair ====== ====== Cylinder / Head Bolt Issues and Repair ======
 ===== Sub Documents ===== ===== Sub Documents =====
-See also [[techtalk:evo:engmech03b|Time-Sert Repair on Engine Case Cylinder / Head Stud Hole]] in the Sportsterpedia for cylinder / head stud repair. +See also in the Sportsterpedia: 
- +  * [[techtalk:evo:engmech03b|Time-Sert Repair on Engine Case Cylinder / Head Stud Hole]] 
 +  * [[techtalk:ref:tools023#warped_or_damaged_thread_repair|Warped or Damaged Thread Repair]]
 ===== Loose Head Bolt Studs ===== ===== Loose Head Bolt Studs =====
 A big concern about the studs becoming loose is the threads being stripped in the case. \\ A big concern about the studs becoming loose is the threads being stripped in the case. \\
 The two side by side bolt holes on the right side in the pic below are each drilled into the opposing holes and tapped. \\ The two side by side bolt holes on the right side in the pic below are each drilled into the opposing holes and tapped. \\
 So each hole is depending, in part, of the strength of the other. \\ So each hole is depending, in part, of the strength of the other. \\
-With the bolts loosening, it is at least suspect that the threads or the hole strength is compromised. ((Hippysmack of the XLFORUM http://xlforum.net/forums/showthread.php?t=2074117&page=2)) \\+With the bolts loosening, it is at least suspect that the threads or the hole strength is compromised. ((Hippysmack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/197474-leaking-head-gasket-loose-head-bolts/page2?t=2074117&page=2)) \\
  
-|  Weakest head stud holes in the case. ((photo by Hippysmack))  | +|  Weakest head stud holes in the case. ((photo by Hippysmack))  |  Head bolt pulled out of the case. ((photo by Blue Scoot of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/198541-repairing-cylinder-studs-cases/page5#post4360678))  | 
-|{{:techtalk:evo:engmech:weakest_cylinder_bolt_threads_by_hippysmack.jpg?direct&300|}}|+|{{:techtalk:evo:engmech:weakest_cylinder_bolt_threads_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:head_bolt_pulled_out_by_blue_scoot.jpg?direct&300|}}|
  
 There is a procedure in the manual for tightening the studs before installing the cylinders and heads. \\ There is a procedure in the manual for tightening the studs before installing the cylinders and heads. \\
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 If a stud is backing out, it could have simply be from it being installed improperly to begin with. \\ If a stud is backing out, it could have simply be from it being installed improperly to begin with. \\
 It is possible that the stud turned when the head cap nuts were removed. \\ It is possible that the stud turned when the head cap nuts were removed. \\
-Heat plays a role in what happens to the studs / nuts also and can lock the cap screw tighter than the stud is to the case.+Heat plays a role in what happens to the studs / nuts also and can lock the cap screw tighter than the stud is to the case. \\
 So it is possible that the top nut was just tight to the stud before breaking loose. \\ So it is possible that the top nut was just tight to the stud before breaking loose. \\
 First try and remove any studs that back out and check the threads in the case as well as the stud. \\ First try and remove any studs that back out and check the threads in the case as well as the stud. \\
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 This made removing the stud with an 18" pipe wrench easier the next day. \\ This made removing the stud with an 18" pipe wrench easier the next day. \\
 {{:techtalk:evo:engmech:stuck_cylinder_stud_removal_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:stuck_cylinder_stud_removal_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack))
- 
  
 ===== Stud Removal ===== ===== Stud Removal =====
  
 ==== Using stud removal tools to loosen the stud ==== ==== Using stud removal tools to loosen the stud ====
- 
 |{{:techtalk:evo:engmech:bent_socket_ext_while_removing_cylinder_stud_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:broken_stud_extractor_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:damaged_cylinder_stud_while_removing_by_hippysmack.jpg?direct&300|}}| |{{:techtalk:evo:engmech:bent_socket_ext_while_removing_cylinder_stud_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:broken_stud_extractor_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:damaged_cylinder_stud_while_removing_by_hippysmack.jpg?direct&300|}}|
- 
  
 ==== Using a pipe wrench to loosen the stud ==== ==== Using a pipe wrench to loosen the stud ====
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 You just have to find a way to make the wrench bind against the stud. \\ You just have to find a way to make the wrench bind against the stud. \\
  
-|If the wrench doesn't grip, make it bind on the stud.  ((photo by Blue Scoot of the XLFORUM http://xlforum.net/forums/showthread.php?t=2074117&highlight=head+gasket&page=6))  |+|If the wrench doesn't grip, make it bind on the stud.  ((photo by Blue Scoot of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/197474-leaking-head-gasket-loose-head-bolts/page6?t=2074117&highlight=head+gasket&page=6))  |
 |{{:techtalk:evo:engmech:removing_cylinder_stud_with_pipe_wrench_by_blue_scoot.jpg?direct&300|}}| |{{:techtalk:evo:engmech:removing_cylinder_stud_with_pipe_wrench_by_blue_scoot.jpg?direct&300|}}|
  
-==== Using Double Nuts ====+==== Using Double Nuts / Jam Nuts ==== 
 +Install 2 nuts on the top threads and torque the two nuts to 35ft pounds or higher. \\ 
 +Be aware the tall studs can stretch if it takes too much torque to break them free. \\ 
 +Be sure to use rags around the bore so as to not get any debris in the engine while removing the stud(s). \\
  
-===== Stripped Case Threads =====+|  Three jam nuts used here. ((photo by A 4 liter V8 eater of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/148266-building-a-90-inch-sledge-hammer/page11#post3236162))| 
 +|{{:techtalk:evo:engmech:tightening_cylinder_-_head_studs_by_a_4_liter_v8_eater.png?direct&300|}}|
  
 +===== Cleaning the Case Threads =====
 +The threads on the head studs as well as in the case need to be clean and free of rust / debris and they need to be straight in order to obtain proper torque on the heads. \\
 +
 +The photos below are of before (L) and after (R) chasing the case threads with a 3/8"x16 tap. \\
 +The dirty threads will add preload to the torque readings and can easily give false readings on the wrench which could affect head gasket performance. \\
 +
 +{{:techtalk:evo:engmech:head_bolt_threads_before_chasing_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:head_bolt_threads_chased_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\
 +
 +===== Stripped Case Threads =====
 These could be repaired with Heli-coils. \\ These could be repaired with Heli-coils. \\
 But the repair must be straight with no wobble when drilling. \\ But the repair must be straight with no wobble when drilling. \\

Trace: • REF: Tools - 140 • EVO: Engine Mechanicals • EVO: Engine Mechanicals - Sub-03A • EVO: Engine Mechanicals - Sub-03F