Removing Side Engine Cover - XR250

Discussion in 'Motorbike Technical Discussion' started by bhalicki, Aug 24, 2005.

  1. bhalicki

    bhalicki Guest

    Hi all,

    I'm about to remove the left hand side engine cover on my XR to replace
    a weeping gasket and wanted a few tips to avoid stripping out threads.
    The hex type bolts seem damn tight, I didn't want to force them incase
    it strips out the case threads.

    Any ideas?

    Thanks in advance,

    bhalicki, Aug 24, 2005
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  2. wrote in
    My feeling is that if the threads are seized to the bolt, they are seized
    and no matter how you take them off they are going to be history. If they
    arent siezed, then you are good to go. Just don't get too energetic
    putting it back together. Just take to cover off when you have plenty of
    time of get a helicoil kit. Helicoils work great as long as you take your
    time and understand how they work. The kits comes with a guide that
    obscures the starting threads. I have never had any luck using that guide.
    Take it off so you can see what you are doing.

    R. Pierce Butler, Aug 24, 2005
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  3. Ah, yes, the Japanese factories do put their engines together with the
    intent that they stay together and when loosening factory-tightened
    bolts I will hear a *squeak!* as the threads release their grip.

    Back in the olden days, when the Japanese factories were installing
    phillips head screws, home mechanics would be buggering out the screw
    heads. So we quickly learned that we needed impact wrenches to take
    out. The impact wrench we bought was hand held, and reversible, but we
    hit it with a hammer to break the bolts loose. I suppose these impact
    wrenches are still available at motorcycle $tealer$hips, but you can
    also buy one from (part number 28-08 in the paper
    catalog is probably 2808 in the online catalog).

    Or, if you have a small air compressor and and air-driven impact wrench
    set on low, that would be a good way of gradually getting the cover
    bolts to let go.

    Another way would be to put a tight-fitting socket (I suppose the bolt
    head are 8mm )and give the socket a sharp whack with a hammer on each
    before applying torque to remove it. That's why those hammer-driven
    impact wrenches were invented.
    krusty kritter, Aug 24, 2005
  4. yeah, I got an impact driver from canadian tire for $35 and I dont know
    how much pain and suffering it has saved me. Fits all my ratchet bits
    and comes with some high quality screwdriver heads too. Works like a charm.
    jellybean saint, Aug 24, 2005
  5. bhalicki

    bhalicki Guest

    Thanks for that info guys, I'll let you know how I go, or how many
    helicoils I have to fit!


    bhalicki, Aug 24, 2005
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