TOPIC:

Yeah, but not enough heat; propane won't do it.  A friend of mine has an acetylene torch but I'm afraid it might melt the aluminum. 

Drilling it out IS an option, but I think that'll be my last resort.

Map gas is hotter than propane. It should be enough just to expand the aluminum a tad.

You should be soaking the broken bit with Kroil or similar. While your searching for a repair option.

wrote:

You should be soaking the broken bit with Kroil or similar. While your searching for a repair option.
 

Exactly!  Ed

pm sent.  
just noticed this head is tapped for 18mm plugs, my 79 has 14mm plugs.  weird.  maybe it's not for a 79 ?

edit:  the spare cyl head is bored/tapped for the oil line, but the casting numbers are different.  maybe it's for a 79' - '80 but the PO drilled for 18mm plugs? 

I decided to start at the top and work my way in - doesn't look too bad inside - 
 
 

But the only problem I have right now is getting to the master link...I can rotate the kickstarter but it doesn't seem to be attached to the crank!  It doesn't catch on anything, just seems to rotate through ... Am I missing something obvious here? I'm currently trying to get the right side cover off; all the bolts are out but she doesn't want to give it up off of that stubborn seal the kickstarter shaft goes through...

The points are toast, as I expected...
 

...and the spark advance is too hideous for publication. No pic though.

Comments...?

But the only problem I have right now is getting to the master link...I can rotate the kickstarter but it doesn't seem to be attached to the crank!  It doesn't catch on anything, just seems to rotate through ... Am I missing something obvious here? I'm currently trying to get the right side cover off; all the bolts are out but she doesn't want to give it up off of that stubborn seal the kickstarter shaft goes through...
 

The cam chain doesn´t have a master link, it´s a endless rivet chain type. You have to remove the cam chain sproket first.

 

Gosh, is that all...??

Good thing I have a shop manual. 

to prevent the cam chain from dropping i suspended mine during head and cyl removal, a little tricky during reassembly.  if the kickstarter doesn't appear to be connected to anything, i believe access to it can be accomplished by flipping the engine over and removing just the bottom case.  the gear train will remain in the upper case, the kickstarter assembly remains in the lower case.  pics are from my 79 kz400 during cleaning and reassembly.  good pic of kickstarter assy in pic#2.