Well this really sucks

[Beebop]

I've done roughly 19000km in the past 18 months (04 XB9SX). I replaced the plugs
at 30000km, and the bike now has 49000, so new plugs are due at its
next service. Well I never got that far.
On the way home yesterday , just overtaken a car at about 140kmph, and just about to
exit the highway, I lose the rear cylinder.
Can't explain why after 19000km it decided to climb out, but it is what it is.
So now the motor has to come out, I want to replace the noisy hydraulic
lifters. Are these easily come by, and are there Harley ones that can be fitted.
Note I'm in South Africa where Buell parts are just not available.


And of course this would happen while my other bike (04 1150GS) is
undergoing some much needed maintenance at 150000km.

 

[Chicknstripn]

I have a set of old stock lifters if you want them

 

[arikam]

Why does the engine need to come out? You should be able to fix a spark plug hole with a good heli-coil set or keensert. I prefer the keensert myself but a heli coil may work better for you in a tight spot.

 

[Chicknstripn]

I'd recommend rotating the engine so that the rear head can be pulled.
Don't want metal shavings falling into to cylinder head.
Also, good luck getting a drill, tap, timeset or whatever into that rear head. It's obviously hard enough to get a spark plug in there!

 

[rchuff]

If you apply grease to the tap it catches almost all the shavings . If a little gets in cylinder it doesn't hurt it will blow out exhaust. Have done a bunch.

 

[Chicknstripn]

Well......
Said it before and I'll say it again..... learn something new just about everyday around here

 

[rchuff]

Learned the grease thing working on a lot of small engines.

 

[Cooter]

I'd do the grease trick on a lawnmower, tap a little, remove, clean, re-grease, tap a little more, remove, clean re-grease, etc.

IMHO on a motorcycle (one you like), it's worth the afternoon (3 beers) to rotate and pull the heads, I'd insert both heads. It's not that hard to rotate and the easy access guarantees you'll tap it square. Besides, you need lifters anyway/ rocker gaskets/ etc. How are the jug gaskets on a bike with 50k on it? Lots of might-as-wells while your in there.

 

[34nineteen]

^^^^ This would be my take on it as well.

 

[Beebop]

I have a set of old stock lifters if you want them

Thats most kind of you .
I'm going to try get some locally, but if not, I may be knocking on your door to do a shipment for me.

 

[Beebop]

I'd do the grease trick on a lawnmower, tap a little, remove, clean, re-grease, tap a little more, remove, clean re-grease, etc.

IMHO on a motorcycle (one you like), it's worth the afternoon (3 beers) to rotate and pull the heads, I'd insert both heads. It's not that hard to rotate and the easy access guarantees you'll tap it square. Besides, you need lifters anyway/ rocker gaskets/ etc. How are the jug gaskets on a bike with 50k on it? Lots of might-as-wells while your in there.

Exactly why I want to pull the motor and check everything out. She does 80km a day, 80% of that at 140kmph( 4500 - 5000 rpm), so its
not being used to knock around the suburbs on weekends.

 

[Subarubrat]

And as long as your pulling all that, it is an easy thing to install a big bore 1275cc kit, now you have a new bore and pistons in the mix too. And you could just have them fix the plug holes while your getting the heads ported then you have an entire new top end. As long as your pulling it apart why not go all in?

 

[Beebop]

Just to close the loop on this.
I did pull the top and and jugs off front and rear, nothing wrong with bores, rings or crank.
Had timeserts installed in both heads. Waited for months for a top end gasket set.
I also pulled apart, cleaned and re-assembled the lifters
Last weekend I put it all together and started her up, Runs like the good old
days again. I still need to do a TPS reset, but even after 100 odd miles she seems
fine.
2 Issues outstanding, none relating to the failure:

1. The fan seems to run more than it did in the past.
2 The clutch still drags. This was expected as I never did anything to it. This will
be my next job in about 2 weeks time.

very happy to have my commuter up and running again. The 1150GSA just
isnt the right tool for that job.

Cheers and thanks to Chicknstripn for the offline advise and support.

 

[Lusiphur]

Wow

Well done!!!