Maintenance & Technical > KX500 Original

Cylinder Stud Removal

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hughes:
Hey Guy's I got the bike torn down and I'm getting ready to remove the studs from the cylinder. I was thinking a stud runner and spray some kind of penetrating lube. Any other idea's for removing these studs?? They look like it's not going to be fun.

Timbowe:
Lock nut them. Dont use any heat could warp the barrel.

KXcam22:
Hughes,
  Double nut on the stud and then spin them out (since they are threaded).  No heat. Should come out quite nicely.  After they are out check the threads in the cylinder to make sure they are in good shape. I once had an engine with one stud creeping (bad threads) and blowing the head gasket. Took me forever to figure out what it was. Cam.

hughes:
Thanks Guy's. I just wanted to make sure before I tried it. The cylinder replate guy wants 60.00 buck for removing these studs if I leave them in.

barryadam:
If they are really stubborn, and double nuts aren't working too well, try this:

I apply Kroil penetrating fluid for at least overnight.
Get some aluminum jaws for  your bench vise.  The kind that have some v-slots machined into the aluminum faces.

Clamp one stud at a time as hard as you want in those aluminum jaws, turning a bit at a time , reclamping as needed.  Obviously, working the first stud, you only get a few degrees of rotation in the vise.

After removal of all the studs, chase the threads on the studs and in the cylinder with a thread restorer, NOT a  tap and die.  I find all of the threads get slightly stretched.  Check to be sure they will all hand thread all the way in again.  I have the studs plated with the rest of the fasteners and reassemble with plenty of anti-sieze.

Take advantage of the bare cylinder by cleaning up the head surface on a surface plate along with the head itself.

Barry

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