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XT cylinder head - exhaust flanges corroded in.. XT cylinder head - exhaust flanges corroded in..
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by George Guille, It's going to be a long 300km... Bolivian Amazon

I haven't been everywhere...
but it's on my list!


Photo by George Guille
It's going to be a long 300km...
Bolivian Amazon



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  #16  
Old 6 Jul 2013
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How do you upload pics on here? It says enter a URL??? My pics on my computer not online....
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  #17  
Old 6 Jul 2013
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Quote:
Originally Posted by lowbudgetrider View Post
How do you upload pics on here? It says enter a URL??? My pics on my computer not online....
You need to host them on the web. Use websites like photobucket etc. Once uploaded, right click the photo and get the URL address. Copy and paste this into the hubb dialogue box.

Comprende ?

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  #19  
Old 6 Jul 2013
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Damn this look nasty! Now iam even more glad i bought stainless steel pipes. Dremel is the key word here, alot of different grinding and cutting and it will be good. In the end when you have come down to the last parts of steel you can heat up with heat pistol and use alot of rust remover, then try to tap on the steel it maybe come of. Good luck.
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  #20  
Old 6 Jul 2013
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Damn.... Thats sucks
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  #21  
Old 6 Jul 2013
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Can you get a slide hammer to grab with some sort of fingers to jar them out?
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  #22  
Old 6 Jul 2013
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Wow. Not good.

How about this:

Soak in rust remover for a few days.

Wedge a small screwdriver (using a small hammer , don’t go crazy) between the steel and aluminum to break the bound. That should also help to get the rust remover a little deeper the next time.

Repeat.

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  #23  
Old 7 Jul 2013
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Hi
looking at the pics, it looks like you are only trying to remove the pipes.
Might be a silly question, but you do realise that the remaining thick steel band is part of the headers(and is welded to the header pipe on the cylinder head side) and must be removed.
Bob
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  #24  
Old 7 Jul 2013
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Bobmech: you're totally correct! I also missed that!

lowbudgetrider: have someone grind away some rust from the outside pipe and make a weld on there, give it a couple of taps with a hammer and just pull that thing out there!
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  #25  
Old 7 Jul 2013
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This is how the cylinder head should look like without those headers in there:

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  #26  
Old 7 Jul 2013
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Wow.....

That's terrible. Where was the bike stored ? At the bottom of a canal ?


Forget a tiny screw driver.. It will just snap and make a mess.

You need a flat chizzle and a blow torch now.


Those studs are also rotten but at least they're protruding. They also need a lot of heat on them and some nuts welded on top of them.
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  #27  
Old 7 Jul 2013
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Are you shitting me? That whole ring protruding from the head had to come off? I thought that was part of the head? Not the header..!?!? Assumption truly is the mother of all f**k ups, Bobmech.. Thanks so much for your help!! I have fresh hope!
As for cleaning it up I've been experimenting with a home made sodablaster... any thoughts??
Thanks for all the help everyone...
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  #28  
Old 19 Jul 2013
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The head is alloy so if you rub the ring part with a file you will soon tell if the metal is alloy or steel.

I'm thinking oxy torch, get the steel red hot and let it cool, repeat a couple of times and see if it comes loose.

If it all comes out like crap you can bore it out a little and turn up some collars out of 6061 and press them in to get the original bore size for the pipes.

Good luck, Dave
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  #29  
Old 9 Aug 2013
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Did you get any luck fixing problem? When i look at pictures ian thinking this must be a reduced header, 34HK? What you have drilled into is not on a normal 600.
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  #30  
Old 10 Aug 2013
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The OEM manual says use a blow torch and WD40.

As Ted says above, a cold chistle is a good idea too (I'm Touring Ted's greatest follower).

I think that most if not all bikes will need this treatment not just those that haven't been looked after. Over time they become almost impossible to budge using conventional spanners.

Mine still wear OEM exhausts (you know the ones - those huge black heavy things). They are very quiet though. When I last tried to loosen the manifolds they were impossible to move in any direction. Mine are minters and spend winters tucked up in my garage covered in WD40 and GT85 with a dust cover.
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