Register    Login    Forum    Search    FAQ

Board index » Hornet 600/599 » Mechanical & Electrical




Post new topic Reply to topic  [ 15 posts ] 
Author Message
 Post subject: Helicoil plug threads
 Post Posted: Sun Feb 04, 2018 9:03 pm 
Offline
Hornet Baby

Joined: Mon May 29, 2017 1:14 pm
Posts: 21
I need to helicoil one of the spark plug holes (the one thats a bugger to get to!).
Is there any way to do this in situ or does the engine have to come out and head off?
Any suggestions for an engineer to sort it in Croydon/Surrey area?
Thanks, Bob


Top 
 Profile  
 
 Post Posted: Mon Feb 05, 2018 1:30 pm 
Offline
Hornet Warrior
User avatar

Joined: Sun Sep 04, 2016 11:28 am
Posts: 108
Oh. That's PITA. I don't really imagine a way to helicoil it without removing the engine head. I believe the head can be removed with the engine still in the frame. You will only have to replace the gaskets.

_________________
Honda Hornet CB600F 1999


Top 
 Profile  
 
 Post Posted: Mon Feb 05, 2018 6:57 pm 
Offline
Hornet Baby
User avatar

Joined: Sat Aug 20, 2016 6:39 pm
Posts: 31
Location: Lower Saxony, Germany
If it's a bugger to get there with a spark plug, it will be even worse to get there with a helicoil tool. The second reason is that the chips from the drill would get into the engine.

_________________
Cheers,
Michael

1998 CB600F PC34
2003 CB900F SC48
2001 CB500S PC32
1981 XL185S L185S


Top 
 Profile  
 
 Post Posted: Mon Feb 05, 2018 8:45 pm 
Offline
Hornet Baby

Joined: Mon May 29, 2017 1:14 pm
Posts: 21
Well there are ways of stopping swarf going down the plug hole but it prob does need to come off.
Any ideas how the head comes off with engine in place? It looks unlikely. I presume theres a way of withdrawing the studs?


Top 
 Profile  
 
 Post Posted: Mon Feb 05, 2018 9:10 pm 
Offline
Hornet Baby
User avatar

Joined: Sat Aug 20, 2016 6:39 pm
Posts: 31
Location: Lower Saxony, Germany
We are talking about the PC34/36 series, aren't we?
Yes, according to the manual it should be possible to remove the head while the engine is built-in.
Exhaust, carbs, cams, PAIR system and radiator/fan must be removed first.

_________________
Cheers,
Michael

1998 CB600F PC34
2003 CB900F SC48
2001 CB500S PC32
1981 XL185S L185S


Top 
 Profile  
 
 Post Posted: Tue Feb 06, 2018 7:20 am 
Offline
Hornet Baby

Joined: Mon May 29, 2017 1:14 pm
Posts: 21
No, it"s a PC41 (2010 F9). Is it still possible? There does appear very little space even for withdrawing studs.


Top 
 Profile  
 
 Post Posted: Tue Feb 06, 2018 10:28 am 
Offline
Hornet Baby
User avatar

Joined: Sat Aug 20, 2016 6:39 pm
Posts: 31
Location: Lower Saxony, Germany
Well, I do not know the details about the PC41. However, if you remove the top-end-cover and the camshafts, it could be possible.

_________________
Cheers,
Michael

1998 CB600F PC34
2003 CB900F SC48
2001 CB500S PC32
1981 XL185S L185S


Top 
 Profile  
 
 Post Posted: Sat Feb 10, 2018 6:08 pm 
Offline
Hornet Lord

Joined: Sun Feb 07, 2010 7:19 pm
Posts: 619
Location: Surrey
You're not far from tippets in Tolworth and they are not going to mess it up.

_________________
Colgster

-------------------------------------------------------------------------------------


Top 
 Profile  
 
 Post Posted: Sat Feb 10, 2018 6:09 pm 
Offline
Hornet Lord

Joined: Sun Feb 07, 2010 7:19 pm
Posts: 619
Location: Surrey
Or there is dobles

_________________
Colgster

-------------------------------------------------------------------------------------


Top 
 Profile  
 
 Post Posted: Sun Feb 11, 2018 3:30 am 
Offline
Hornet Baby

Joined: Mon May 29, 2017 1:14 pm
Posts: 21
Well I've been having a read up of the manual and apparently the head can be removed with the engine still in the frame. I've found an engineer a few miles away who can sort the helicoil so I have a plan!


Top 
 Profile  
 
 Post Posted: Wed Mar 14, 2018 9:25 pm 
Offline
Hornet Lord

Joined: Wed Sep 26, 2012 9:57 pm
Posts: 611
Might be a bit late but give this a watch. I know it’s not ideal doing it without removing the head but it is possible and is commonly done.
https://youtu.be/Cqid0tfLzEg

_________________
"If you don't lose traction going in, getting to 40/60 won't make it crash, it will make it handle"
Image


Top 
 Profile  
 
 Post Posted: Mon Apr 09, 2018 10:40 pm 
Offline
Hornet Baby

Joined: Mon May 29, 2017 1:14 pm
Posts: 21
I've seen thst done and even helicoiled car heads in situ but the plug holes on a PC41 are impossible to get to with a tap.
It was a bit of a pain but I took the head off and got a local engineer to do the thread. All back together now. The whole thing was about 5hrs off and on again.
Most difficult bit was getting the damned airbox off!


Top 
 Profile  
 
 Post Posted: Tue Apr 10, 2018 10:36 am 
Offline
Needs to get out more!
User avatar

Joined: Mon Jul 13, 2015 8:08 am
Posts: 1487
Location: In The Garage
Well done :clap must be a relief to have it all sorted :D


Top 
 Profile  
 
 Post Posted: Tue Apr 10, 2018 1:22 pm 
Offline
Hornet Baby

Joined: Mon May 29, 2017 1:14 pm
Posts: 21
Yep she's buzzing again. :rollin

A point of interest is the bore condition when I got the head off. There was very little wear on the bores at all. Even though its a hi-miler at 45k miles, the bores were immaculate, still showed the original honing and the piston tops just a very light coating of coke. Likewise the heads and ports all still clean and crisp. Judging by the gaskets and clips I'm pretty sure the head's never been off before. These engines were certainly built to last!


Top 
 Profile  
 
 Post Posted: Tue Apr 10, 2018 2:17 pm 
Offline
Needs to get out more!
User avatar

Joined: Mon Jul 13, 2015 8:08 am
Posts: 1487
Location: In The Garage
That's impressive - my bike is also around the 45k mark - these CBR engines do have a well proven record of reliability and longevity - hence the US CBR600 guy who has racked up 300,000 trouble free miles on the same engine.


Top 
 Profile  
 
Display posts from previous:  Sort by  
 
Post new topic Reply to topic  [ 15 posts ] 

Board index » Hornet 600/599 » Mechanical & Electrical


Who is online

Users browsing this forum: No registered users and 2 guests

 
 

 
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum

Search for:
Jump to: