XBR500 head gasket

[richardeblack]

Hello All
Two problems have raised their nasty heads, both related. I have an exhaust stud broken on my new XBR and would like to get it out without taking the head off. It is broken flush. Any one had any success?
The related problem is that I think I will have to have the head off to do it and head gaskets are suddenly rare and horribly expensive. Honda have discontinued them according to David Silver. The cheapest I've seen are over £30! Annoying when Xl ones are only a tenner.
Any ideas please?
Here's hoping.
Cheers
Richard

[mthee]

themouldie's tip of using left handed drill bits worked on a sheared off fork clamp bolt for me. I went 3mm, then 4 and didn't need the 5. An auto centre punch to start, as you probably already know.

Halfords do a freeze spray, "Shock & Unlock" to use before the heat generated by the drilling, if it's corroded, but I can't vouch for it myself.

http://www.halfords.com/motoring/paints-body-repair/rust-removal-treatment/halfords-shock-unlock-spray-400ml

No idea on head gasket prices, but SteveC#222 always has his finger on the XBR pulse.

Good luck!

[iansoady]

I've never had succes with that freeze spray stuff although other people rave about it.

I can endorse the use of left handed drill bits - I currently have a little job on my Discovery that will require them.....

[timbo]

Just ordered a set of leftie drill bits. A great tip 

[richardeblack]

Than chaps
I will have a go with a left handed drill when I can get one. Of course the only one on Amazon I wanted (4mm) isn't on prime but will try our excellent tool shop. Any suggestions for easy outs? I have had cheap ones twist or break and don't want that!
That's my job for the weekend.
Thanks
Richard

[Moto63]

Best of luck with it Richard. Keep us updated of progress. Cheers, Michael

[themoudie]

Aye Richard,

Don't use 'EasyOuts', if they snap you then have tempered steel to deal with, rather than mild steel.    Often when you are at that stage, welding another bolt onto the remains in the head (risk of warping the alloy etc) or spark erosion, are the only options; neither are cheap and require good engineers.

Buy a "quality" (money!) set from a reputable tool suppliers, rather than Amazon (Chinese cheese), they may not be tempered correctly, and work your way slowly up through the drill sizes, being prepared to use helicoil inserts if necessary. Once you have the offending bits out, replace all exhaust studs with stainless steel studs and use phosphor bronze nuts, all put together with a touch of 'Copaslip'. No more seized nuts! 

I trust this helps.

My regards, Bill

[iansoady]

I got my left handed bits from ebay some years ago.

For instance: http://www.ebay.co.uk/itm/Left-Hand-Spiral-M35-Cobalt-Drill-Set-3-6mm-/252605904523?hash=item3ad07c368b:g:OqsAAOSwHsRYENuy

[mthee]

These are the Dormer bits I used, recommended to me and available on Amazon;

https://www.amazon.co.uk/gp/product/B0001OZNY8/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1

[timbo]

I have a set of easy outs, which I have never used with any success. Plus you spend most of the task crapping yourself, that they will snap. Then, as Bill mentioned, you are up Sh!t Creek.

[Moto63]

Oooo......sh1t creek, easy out and sized nuts....oooo all sounds pretty painful to me

[SteveC#222]

Aye Richard,

Don't use 'EasyOuts', if they snap you then have tempered steel to deal with, rather than mild steel.

+1
Been there, did that, buggered up the barrel!!

Can't help with cheap head gaskets, they all seem to be a similar price and Wemoto don't appear to do them.

If you have to bite the bullet it might be an idea to use Dave Silver as at least you'll get a good quality product... I'm always a bit dubious of some of these Ebay sellers.

[richardeblack]

Thanks for all the suggestions folks.
I have just those fears about easy outs . I have broken one before. In the old days I used to run a spark eroder but now work in a fine art department!!! Therefore I am jiggered if one breaks.
I think I will make up a template for drilling to get it central and square an see how I go with good quality left handed drills although I am just as scared about breaking one of those off!
On the subject of head gaskets, I spoke to David Silvers people at the show and the XBR head gasket is no longer available! Stuck with pattern ones between £38 and £63 so far unless I try the suggestion given at the show of making a copper one. Not sure how well that will work. Any ideas?
Thanks
Richard

[themoudie]

Aye Richard,

This will need checking; but, I think that the Honda Part Number 12251-MK4-602 cylinder head gasket fits the XBR as well as the XR500! This needs to be confirmed!

Might I suggest that you contact one or both of the following, giving full details of the model, engine number, bore etc.

Firstly, contact 'Eastwood Racing' at Swanley in Kent, they are the Wiseco Importers and stockholders for the UK and I have used them for replacement SRX cylinder liners, pistons and matching gaskets, all good quality and good advice if requested.

Eastwood's Home page: Eastwood_Honda_Racing

Eastwood's link to Wiseco Honda cylinder, piston and gasket sets: Wiseco Honda cylinder, piston and gasket sets.pdf

Alternatively, I suggest that you contact Mark Apland in USA. He has a goodly list of items for the Honda GB500, but not having dealt with XBR's and GB500's I cannot say about their interchangeable specific dimensions. Link: Mark_Apland's_'Thumper_Stuff'

Hopefully between them these two suppliers should get you and others out of a hole, with parts of known quality and reputation.

Lastly, and an unknown quantity to me are these Dutch suppliers; worth a call if others cannot oblige: CMS_Nederland

My regards, Bill

[SteveC#222]

If gaskets are starting to get hard to find it might be worth investing in one of those full top end gasket sets - they are more expensive but at least you have all the spares you are liable to need ... might do that myself.