Magician exhaust plate stud broke off and pipe broken from frame - Page 2

pcast01 · 05-17-2018, 01:10 PM

Quote:

Originally Posted by Megadan

Just going to make this suggestion, but if you take the head in to a local machine shop, they can probably extract that stud without damaging the threads for a relatively small fee.

Worst case scenario, order a replacement head through CSC for the TT250. The only real difference will be that you need to make a block off plate for the air injection port on the exhaust side. $85 for a complete head already painted black and ready to go.

Just curious but how hard is it to remove just the head??

Megadan · 05-17-2018, 01:13 PM

The head comes off the engine rather easily. remove the valve cover. remove the 3 bolts that hold on the rocker assembly, remove the push rods, remove the 4 nuts that hold the head to the cylinder. remove head. Just make sure to set the engine at TDC on the compression stroke before you begin, this will ensure you are not fighting the valve springs when removing or installing any of the components.

Now, if it can be removed from the engine while installed in the frame of the Magician is a question I can't answer. It can be pulled from the Hawk, and most likely it can be done with the Magician too, but I have no first hand experience.

Weldangrind · 05-18-2018, 12:25 PM

Quote:

Originally Posted by JerryHawk250

??? what you been smoking?

That's the cylinder head.

I have no excuse for that; not sure what I was thinking.

pcast01 · 05-21-2018, 08:58 PM

Quote:

Originally Posted by zippy

This shows how I used my head I already had. The newspaper kept the metal shavings out of the cylinder head while work was in progress:

So my newest update, I had a good friend come over and help me try to remove the stud and we first tried to remove the other stud to see how far we needed to drill but it broke off almost immediately. So we tried to remove that one and no luck. So I am looking at doing what you did zippy.

Quote:

Originally Posted by zippy

A machine shop I consulted recommended I drill the new holes to a depth 1.5 times the diameter of the replacement studs.together.

How far did you say to drill? 1.5 times the diameter??

zippy · 05-22-2018, 08:19 AM

That's right. The machine shop guy said standard practice is to go to a depth 1.5 times the diameter of the replacement stud. I did and the depth of the metal in the head was sufficient to take it.

Good luck. It was tricky to drill the holes perpendicular to the face but I got them close enough to work.

05-17-2018, 01:13 PM	#17
Megadan Join Date: Apr 2017 Location: Omaha, NE Posts: 7,976	The head comes off the engine rather easily. remove the valve cover. remove the 3 bolts that hold on the rocker assembly, remove the push rods, remove the 4 nuts that hold the head to the cylinder. remove head. Just make sure to set the engine at TDC on the compression stroke before you begin, this will ensure you are not fighting the valve springs when removing or installing any of the components. Now, if it can be removed from the engine while installed in the frame of the Magician is a question I can't answer. It can be pulled from the Hawk, and most likely it can be done with the Magician too, but I have no first hand experience. __________________ Hawk Information and Resource guide: http://www.chinariders.net/showthread.php?t=20331 2018 Hawk 250 - Full Mod list here. http://www.chinariders.net/showpost....62&postcount=1 2024 Royal Enfield Shotgun 650 https://chinariders.net/showthread.php?t=34124
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05-22-2018, 08:19 AM	#20
zippy Join Date: Jun 2016 Posts: 11	Depth for Holes to Receive Exhaust Studs That's right. The machine shop guy said standard practice is to go to a depth 1.5 times the diameter of the replacement stud. I did and the depth of the metal in the head was sufficient to take it. Good luck. It was tricky to drill the holes perpendicular to the face but I got them close enough to work.
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