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Repairing cam cap bolt hole

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    Repairing cam cap bolt hole

    Looking in the head of my GSX750e I can see there's an Allen key stuck down one of the cam cap holes:



    Any ideas for the best way to get it out? (Ezy out or magnet?)

    Then the second problem is that this motor is still missing two cam caps.....

    I have another engine but it has 3 stuck exhaust valves & a damaged rocker cover.

    Tossing up whether to fix it or pinching the caps off of it & having them machined to fit this engine
    don't ask to ride my bike and i won't ask if i can shag your missus

    #2
    If you're missing caps its going to need a line bore if you use any from another motor. Theres no guarantee it'll be straight enough though or wont twist when tighten down and be outside the tolerance for new bearings though. So you might just be opening up a huge can of worms and the bolt is the least of your troubles.

    But on to the bolt, drill into it and try and extractor for sure if you think its threaded. Use a good screw extractor, not an e-z out though, the flutes are way too big to be useful, the spline type does a better job. Doesn't really look like an allen key though as the sides arent flat, it even looks like it might just be wedged in there, not actually engaged in any of the threads? Did these things use anything torx related? looks kinda like the head of a e-torx bolt.


    If its not threaded, id probably be drilling and tapping it, screwing a bolt into it, then trying to pull it out with a slide hammer. In fact, id probably try thats first as the spline type extractor can screw into the hole you drilled and tapped anyway. Its pretty small for a regular sized slide hammer, so you can make a smaller slide hammer out of a piece of high tensile threaded rod, some big panel washers, a nyloc to tighten on the end against the washers (forming a stop) and a decent sized long tube socket to work as the hammer sliding along the rod and hitting against the panel washers.
    Last edited by Madhatr; 23-03-20, 10:00 PM.
    Originally posted by Buford T. Justice
    This happens every time one of these floozies starts poontangin' around with those show folk fags.

    Comment


      #3
      Find another head. You can see the journal has burrs on it. It will be fucked.

      Comment


        #4
        Yeah I figure that one's cactus - was a little hopeful it was salvageable though

        Oh well, looks like getting the other engine sorted it is then....
        don't ask to ride my bike and i won't ask if i can shag your missus

        Comment


          #5
          Originally posted by Madhatr View Post
          If you're missing caps its going to need a line bore if you use any from another motor. Theres no guarantee it'll be straight enough though or wont twist when tighten down and be outside the tolerance for new bearings though. So you might just be opening up a huge can of worms and the bolt is the least of your troubles.

          But on to the bolt, drill into it and try and extractor for sure if you think its threaded. Use a good screw extractor, not an e-z out though, the flutes are way too big to be useful, the spline type does a better job. Doesn't really look like an allen key though as the sides arent flat, it even looks like it might just be wedged in there, not actually engaged in any of the threads? Did these things use anything torx related? looks kinda like the head of a e-torx bolt.


          If its not threaded, id probably be drilling and tapping it, screwing a bolt into it, then trying to pull it out with a slide hammer. In fact, id probably try thats first as the spline type extractor can screw into the hole you drilled and tapped anyway. Its pretty small for a regular sized slide hammer, so you can make a smaller slide hammer out of a piece of high tensile threaded rod, some big panel washers, a nyloc to tighten on the end against the washers (forming a stop) and a decent sized long tube socket to work as the hammer sliding along the rod and hitting against the panel washers.
          Yeah that's the problem - the bike's a basket case & came that way so I've no idea what it is. U thought it looked like an allen key but it could be anything (and I've no idea why it's in there....

          With the work involved I think I may be better off freeing up the exhaust valves on my other motor than I am sorting this out ​​
          don't ask to ride my bike and i won't ask if i can shag your missus

          Comment


            #6
            It looks to me like someone brok off th cam cap bolt, thendrilled it out and broke off an extractor too. That would be a bitch to try and fix...
            Originally posted by Marlin
            Chickens will slip under water in the cover of darkness like a seal team and FUCK YOU UP.

            Comment


              #7
              The broken bits can be removed with EDM. An engineering /machine shop can fix that.

              Comment


                #8
                As above the outer part of that journal on that cam looks rooted.

                Did they have step in them ? To stop end float? Or has some one ground it smaller dia?



                Last edited by 9triton; 24-03-20, 10:20 AM.

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                  #9
                  Not sure??? The inlet cam doesn't have it but it looks pretty neat on the bike ..


                  I'm thinking I'll just put this engine aside as a spare & use my other one (apparently the 83 has a few more hp anyway :D )
                  don't ask to ride my bike and i won't ask if i can shag your missus

                  Comment


                    #10
                    Someone's drilled the bolt and hammered a Torx bit into it. Which is normally fine when you use an impact one, which that doesn't appear to be.

                    Besides that, the head is trashed unfortunately.
                    ​​​​​
                    Originally posted by brewdles
                    In short, some cunt at test and tune had a 250cc honda turning to 11ty and it sounded porn. Do that.

                    Comment


                      #11
                      It may be recoverable with some welding and a line bore. The broken ezy out (what it looks to be) can be either carefully drilled out with a 2.5mm drill bit all around it and if you are very lucky a helicoil will sort it. More likely the thread will be fucked and you’ll be using a larger bolt, or again welding and drilling.
                      It’s unlikely to work out cheaper than finding an unfucked head.
                      Last edited by Jim; 25-03-20, 11:06 AM.
                      Turns out, far too much has been written about great men and not nearly enough about morons


                      Originally posted by seedyrom
                      my neighbours called the cops...... not because of the sound of me working in the garage was too loud, but because i taped a cardboard box to my back, covered my self in vaseline and pretended i was a snail on their lawn

                      Comment


                        #12
                        I'm surprised more of you aren't familiar with EDM (spark erosion) . It's the correct way to deal with broken hardened material like taps and drills. It'll cleanly remove the hardened material without taking out too much around it, then allowing simple thread repair. This is standard stuff for machinists.
                        Last edited by Asteroid; 25-03-20, 11:14 AM.

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                          #13
                          Most aluminium head pours for the last several decades, use chills in these areas to enhance the wear resistance. Unless it was something truly unique and just used for a basic running purposes, line boring is not a good solution for what looks like a munted low dollar head....time for the Jesus test in a large body of water methinks!

                          Comment


                            #14
                            Originally posted by Asteroid View Post
                            I'm surprised more of you aren't familiar with EDM (spark erosion) . It's the correct way to deal with broken hardened material like taps and drills. It'll cleanly remove the hardened material without taking out too much around it, then allowing simple thread repair. This is standard stuff for machinists.
                            I've got 2 die sinkers in the workshop. I don't think it's really standard stuff for machinists anymore though.
                            Originally posted by Marlin
                            Chickens will slip under water in the cover of darkness like a seal team and FUCK YOU UP.

                            Comment


                              #15
                              Its a moot point when he hasn't got the matching cam caps anyway. Even if you could repair the thread, line boring the head with a set of caps from another head is going to be far more costly and might not even be physically possible anyway. Thats the far bigger issue.
                              Originally posted by Buford T. Justice
                              This happens every time one of these floozies starts poontangin' around with those show folk fags.

                              Comment

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