bad day

well i have had much better days. I picked up $150.00 worth of parts from Jeff; and i have ordered about another 300 in parts for my project 650. Yeah i know thats way more than she is worth; but i want a project as much as a bike; and bringing her back from the dead has been fun.


Unfortunatly today i ran into a snag. I a screw broke off in the intake (i was putting on fresh carb boots) and when i used an easy out to remove it the friggin bolt hole cracked down the side. So yeah it broke off; so not cylinder #1 intake boot cannot be mounted.


Long and short of it is i think i need a new head. This sucks; because that head (while old, ugly and with 30,000 miles) was all set and shimmed and ready to go. Now it looks like my project will be even LONGER (i was hoping to be on the road in two or three weeks....).

Sigh. Any sugestions? (i will post pics later; when i find some motivation...)

How bad's she look? Do the pieces fit together? May be possible to get it welded and tapped.

I actually did almost the same thing. I put the silicon on the holder then bolted it on the head, packed it with JB and I still had to fight to get it off this past spring.

I did the same thing too, is it the lower hole or the upper?

Take it to someone who can TIG weld Good ..grind or file it down and retap..a good welder can save the day...

Yes i have the peice that broke off and it fits well, also its the upper hole.

I thought about going the jb weld route; espacally because i would eventually like to replace this top end with a 750 gpz. But im really trying hard not to do anything on this bike half assed... not to say it is not effective; just not the type of repair i want to do.


Now having it tig welded is an idea. Im just wondering how much that will run me? Used heads are on ebay right now for around 100ish but then i would need to reshim and who knows the condition of the threads...sigh.

ONE STUPID SCREW had to go and ruin the whole day

bummer.....i would say get it tigged

take it to a welder, it wont cost that much, should be less than a new one. take the intake with you also so they can get the bolt pattern right

well today got 100% worse.

In trying to get the head to seperate from the jugs i broke 2 fins on my previously perfect motor (both on the jugs) and then instead of getting the head off the base gasket went and now i have the jugs/head togeather and off of the pistons.

This motor ran; it wan not perfect but hell i just wanted it to last for a year so i could ride. this is my first bike. Sigh. I want to start smashing shit now...


so now at the very least if i want to ride it with a head that needed rebuilding origionally (but worked good enough for now) i need to

still get it off the jugs
live with jugs with 2 broken fins
replace the base gasket
get the pistons back in the jugs without breaking a ring
take the jacked up head to a welder and pay $100 to ge t the friggin thing welded; and hopefully hes nice enough to drill and tap it for me.

maybe i will just part the friggin thing and buy something new. i have spent 1000+ on it already....i had about another 500 to go before i got it ride able, now this.

been there done that, dont you just love the school of hard knocks!!!!!!!!!!!!

yeah ive got several degrees from there myself!:whistle: :woohoo: i went to good ol "screw u "

hardr0ck68 wrote:

still get it off the jugs
live with jugs with 2 broken fins
replace the base gasket
get the pistons back in the jugs without breaking a ring
take the jacked up head to a welder and pay $100 to ge t the friggin thing welded; and hopefully hes nice enough to drill and tap it for me.

For future reference, the manual should show pry points for getting head off block. Sometimes a rubber mallet helps. Removing ALL the fasteners makes it much easier

Fins can be welded. Once the welder is set up and running it's not much extra work/cost.

Base gasket is easy to cut by hand with 'exacto' knife.

If welder is not set up...file, drill, tap can easily be done by hand with the head off.