I did something stupid - thoughts on a fix?

Hey guys,

Long time reader, first time poster (at least this year).

I have a 1982 XJ650J Maxim that I picked up a couple of years ago. The bike has been leaking oil from the front of the engine, originally I thought it was the head gasket but in doing some research I started leaning towards the valve cover gasket being the culprit. So I replaced it a couple weekends ago and the leak has slowed, but is still present.

Last night when I was doing some investigation I noticed one of the hex bolts at the front of the motor that clamp the head to the jugs was showing less thread than the other so I attempted to tighten it. It didn't feel like it was being over-tightened but boy was I wrong - the damned stud snapped right off

Looking at the parts diagram, it would appear that it's a stud threaded on 2 sides. Would I be okay to just use a bolt extractor to remove it and install a new stud? I ran the bike this morning for a boot around town and it's (no surprise) leaking more than it was before I snapped the stud.

Any help would be appreciated!

Cheers

 

Yes, remove it any way that you can (it might be tough to do with the head still in place, though). We carry the replacement studs (and nuts) in-stock.

 

Hi Chacal,

Thanks for that. That stud is a standard right hand thread I would have to assume? I'm thinking I'll take the exhaust off for easier access to the stud - hopefully I can do it without removing the head. Should have just left 'not quite well enough' alone... Is there a torque spec for the nut?

Replacement part is HCP2941 ?

 

Correct. Good luck with the extraction, it will be tricky!

 

Fecking 30+ year old bolts do have a tendency to snap - i think I'm on number 7. Console yourself with this - it's better that it snapped with you knowing that it snapped rather than on it's own without you knowing.

Take your time with it - spray it with PB penetrating lube first and leave it over-night - if you need to attack it from below drill a small hole into the end of the bolt to give the extractor something to bite into.

 

It's never stupid to put a wrench on something to see where it's at. More than likely the stud had failed from stretch. Be carefull with extraction. I have heated studs before to get them loose. Perfect example Chevy 6 Litre truck manifold bolts break the heads off all the time. I heat them up cherry red and smack them a few times while cooling down and 90% of the time they just back right out. Sure beats pulling heads off and taking to the machine shop. Just take your time and when you apply pressure to the extractor be aware of it will only take so much before it can break.

 

Once you do get this all sorted, if you didn't already, replace the rubber donut gaskets on the valve cover bolts. Chacal, correct me if I'm wrong, but those donuts help add pressure on the valve cover gasket when the bolts are to torque, and as they get old they lose their springiness. That might be why you still had some leakage with a new gasket.

 

why don't you clean that up real nice and forget it ever happened. because you already stepped in a big pile and you're about to track it in the house.
at least give it a chance to prove it's going to be a problem before you make it a problem

 

You are today's grand prize winner! Pick anything......in this general area, right in here. Anything, below the stereo, and on this side of the Bicentennial glasses. Anything between the ashtray, and the thimbles. Anything in this three inches. Right in here, this area, that includes the Chiclets, but not the erasers.

 

Wow Len, that's real generous. What have you done for us lately?

 

Man, Len's a Jerk.

 

You been on funny beer Len?

 

+1 polock.... damn, wish I would have won...

 

Thanks for the consolation! I'll have to pick up some PB penetrating lube - hopefully via capillary action it will be drawn up the stud, not sure it will make it all the way past the unthreaded middle and up to the top, but no harm in trying. The broken end of the stud has a bit of an angle to it, so I'm thinking I'll go at it with a Dremel and a stone to get it flat for using the extractor.

There is definitely oil slowly leaking from this area, more than before. I've always got a jug of oil in the saddlebag to top up when needed.


I picked up a small C-clamp today that I'm going to attempt to finagle into place for the short term. Hopefully that will slow the leak. If I'm unable to get the stud out, aside from aesthetics, any reason I shouldn't drill straight through the hole and insert a through-bolt?

 

I was going to suggest that you use a C-clamp. Put blue loctite on the threads of the clamp and you might be able to run with it until you have a reason to pull the head. I would not try to extract the rest of that stud in-situ; there's too much risk involved, and not enough space to work in.

 

What is the risk of trying to extract the stud?

 

Drilling crooked and ruining the casting, or snaggging the bit and breaking it off (making the job 3 times as difficult).

 

If you try drilling it out get the reverse drill set from Len...they work like a champ

 

Well I've got the clamp on there - couldn't find my Locktite but I'll keep looking. Put 20km or so on the bike since installing the clamp and it seems to be slowing the leak. Going to ride it like this until winter.

 

Wrap some safety wire around the clamp body and to one of the holes on the frame (the ones the oil cooler would bolt to if you had one). That way if the clamp fails it does not become a hazard to yourself or anyone else.

 

300km later and the clamp holds (without Loctite as I couldn't find mine). I got a black one and in my pointing to and explaining the problem from standing nobody has noticed the clamp.

Much thanks for all the help guys!

 

Any advice regarding taking engine degreaser and a power washer to the front of the motor to get rid of some of the dirt and oil?

 

Considering you already are missing a bolt and oil is running out NOT under pressure, I think a pressure washer would easily drive unwanted stuff IN

 

Perssure washers are not something that you want to use on ANY motorcycle EVER (unless you like degreasing the inside of your wheel bearings, headstock bearings, pushing soapy water into your crankcase, ect.).

 

Well I'm glad I inquired - good plan.