Timing chain noise?

[weasel01]

Wow now I have opened a can of worms....

I'm sure they have never been off since being installed at the factory.

How do you cut them off without damage to the threads?

[steve hawkins]

Hacksaw, hammer and chisel.

1.  Cut the exhaust nut across the thread - i.e. between a pair of 'fins' until you get deep enough to almost touch the threads on the heads.  I.e. when you get close be careful.  But even if you touch them, its no big issue - just stop there.

2.  Get a chisel and mallet and hit the nut with a sharp tap on the cut you have just made, the blow will break the remaining mateial without wreaking the thread on the head.

3.  Repeat on the other side.

The issue is the metals corroding and effectively welding themselves together +dirt and grit getting in.  Lots of water and heat over a long period of time and there you have it.  A couple of weeks and some penetrating fluid might get you out of it as well.  But a nice new shiney set of nuts will show you up as someone who knows what he is about.

Sorry to be the bearer and all that.  But it is a risk think.  Just how lucky do you think you are.  Have you got $400 to have the threads fixed?

[weasel01]

Thanks Steve, I think I'm up to it!

BTW...LOVE YOUR R65 Cafe!

[steve hawkins]

One of the original heads on that machine had a knackered exhaust thread.  Did not find out till the araldite melted and the nut started rattling.  

My R100 nuts have not been of either.  I'll wait till I need to take them off though.  But I will be cutting them off!

Cheers

[weasel01]

Just a couple observations....

1)The finned nuts that are on it are not corroded at all they look almost new? Is it really neccesary to cut them w/o trying to wrench them off first?

2)is it not possible to remove the front cross pipe?

I know , I know wishfull thinking.

[steve hawkins]

It is a risk thing.  You might get away with it.  But just how lucky do you think you are?

You know the history of the bike better than I.

Have you got $400 to have the threads fixed?  

[Bob_Roller]

The front crossover pipe overlaps the header pipe by about an inch on each side, and I'm quite sure the pipe will be difficult to remove, I had to cut a slot on each side, and bend the pipe to get it loose from the header .

The first time you do this job, it can be a real pain, but once you get it apart, and apply anti seize to the areas, it's nowhere near the job the second time .

If you do cut across the threads, use a small file to 'dress-up' the threads, and then use the new exhaust nut to chase the threads, or if you have a thread file, use it instead .

[weasel01]

I'm not lucky at all so I will bite the bullet and order thge replacement nuts today.

[montmil]

...But a nice new shiney set of nuts will show you up as someone who knows what he is about.

Steve, you are the man!

Yo, Ampy... Call Re-Psycle for the exhaust nuts. I got a like-new pair from them for half-price. They are be-u-ti-mous with perfect threads.

Do like me and Mikey... I got the entire header and x-over pipes off my R65 as a complete unit. No difficulty. Sorta a BMW RubicsCube puzzle but it is doable deal.

Monte

[weasel01]

I'll check Re-psycle for future projects but I had already ordered a set of nuts from Bob's Bmw they had them in stock.
I guess tonight I will try my hand at nut sawing ...doesnt sound quite right does it?

[montmil]

I guess tonight I will try my hand at nut sawing.

If you happen to have one of those close-quarters hacksaw blade holder thingy -HomeDepot, Lowes, local BigBox- they are the bomb for this chore.

Install the blade so that it cuts on the pull stroke. You'll have only a little space between the nut and cylinder head but a coarse cut blade speeds things along. You will feel the contact with the head stub threads... stop sawing.

Gently tap a cold chisel into the exhaust nut cut parallel to the saw cut; not downward into the threads. Go slow and protect the stub threads as best you can.

Monte

[weasel01]

I do have one of those close quarter hack saws and a chisel,a fresh keg of Sam Adams Boston Lager and a free evening.....off to the man cave!

[Bob_Roller]

Hold off on the Boston Lager, until the nuts are cut off, or collateral damage me be in your future !!!!

[weasel01]

OK I've cut into the first nut down to where I think I feel the top of the threads.
I'm a little nervous about how hard to tap?

Am I tapping it around or am I looking for it to break?

[Bob_Roller]

You want to break it, I've have never done this, as my threads stripped off with one mighty blow from a 25 pound dead blow hammer .

My best guess is that you should place the chisel so that you are loosening the nut when you hit it with a hammer .

Try not to let the chisel hit the thread area .