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Proper Stuck, Any Bright Ideas?


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#1 Bobos

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Posted 10 November 2014 - 09:22 pm

So, this weekend was do the valves on my commuter ER5 that I bought to enable re-beautification of my 850. Should be an easy job; tank off, un-clip throttle cables, take off thermostat housing,rocker cover off, adjust nice easy screw adjusting valves clearances, put it all back. A day at most taking it easy, done more complicated engines like this and love screw adjust valves despite the more frequent adjustment 'cos they're such a doddle to do.

All went well up until removing the thermostat housing, which looks like this...

http://www.ebay.co.u...=item3ce781e792

The two legs straddle the central cam chain and go down into the cylinder head and are totally stuck in place so the rocker cover can't be removed. Tried release agent, gentle(ish) tapping with a hammer, and eventually hooking a strap under it tying that to a roof beam and lifting the entire bike by the housing leaving it over night soaked in release agent. Nothing, didn't move a millimetre. I can't heat it in case the seals get wrecked and the corrosion cracks just enough to let fluid past but won't allow the pipes to come off. Thought about cutting but worried about getting swarf in the coolant system that'll knacker the pump at a later date.

I can normally see at least one way to sort a stuck something but I'm at a loss this time. On an easy job like this it's all the more frustrating.

Any bright ideas out there in Carpe land?
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#2 leehenty

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Posted 10 November 2014 - 09:33 pm

if water is out try spraying pipe freezer down the legs ? sort of shrink them out ?


Edited by leehenty, 10 November 2014 - 09:34 pm.

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#3 Studley Ramrod

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Posted 11 November 2014 - 10:49 am

:wifgeni:

 

Looks like a pain of a job going off the length of the pipes.


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#4 wigwamclan

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Posted 11 November 2014 - 12:48 pm

Think I read on here somewhere a mixture of acetone and transmission fluid is about as good as it gets as far as release fluids go...when tested against the off-the-shelf stuff it was 25/30% more effective than the best of the rest.........maybe worth a shot.

 

Maybe mix it a little thin ( more acetone ) to start with to help it work its way into the rot. I tend towards Plusgas and get mixed results but it's the best off-the-shelf I've found.

 

Good luck 


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#5 Bobos

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Posted 11 November 2014 - 10:39 pm

I have pipe freezerizering stuff and plenty of acetone and transmission fluid so I'll give them a go, the only other option as suggested to me this evening is to dremel in a shallow slot and hit that with a chisel, cracking the metal rather than cutting so no swarf. The pipe does seem to go a long way into the head and due to the relatively low mileage will not have been removed in the 8 years the bikes been on the road. Common detail across lots of bikes and cars I've had and I've never had a problem before, first time for everything I suppose!
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#6 drumwrecker

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Posted 12 November 2014 - 02:44 pm

Kawasaki Forum, ER5 section???
Or a friendly dealer for advice.
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