Word of warning dont over tighten your bolts on the bike the person before me who had my bike must have over tightened the bolts on the cylinder head and one stripped yesterday and wouldnt tighten again ..painful job but its well on the way from sorting it now..

Had to remove the cylinder head which means taking out numerous nuts and bolts to make room . Its now getting re threaded for the morning where i have the long process of putting it back together for a trial tomorrow night

Gas Gas virtually stripped

Is there a certain way to put the bolts back in ?

Edited April 18, 200620 yr by Lewis-GasGas

There is just the common rule of cross tightening the opposite bolt. You can do them in 2 times increments, first all handtight and then to the specification. Use a momentwrench to be exact. No specialties here.

Maybe the o-ring can be reluctant to keep his groove. Put them in with a dab of grease or liguid gasket sealer.

What put some grease on the bolts before they go back in ?

No, i was refering to the o-rings. The bolt go in, with copperpaste the most. The nuts go on dry to have proper torx readings.

wow.. did you have to take off everything just to get the cylinder head off?

Pretty much so everything above it radiator was a faff to get out.

What put some grease on the bolts before they go back in ?

<{POST_SNAPBACK}>

NOOO ! Torqued bolts on engine parts should be dry, no lube of any kind.

Sorted now everything back together ready for me to ride in about an hour

I have this exact problem on a 2005 TXTpro 250 that I got cheap off my brother-in-law. I have a friend with a machine shop so was going to take the head down to him to sort it as I'd read that helicoils (my original plan A) aren't the best job for this sort of repair.

Or would I be better to just take the whole engine out to reduce the number of gaskets etc required.

...and while I'm hijacking the thread, Is there a go-to UK or Ireland distributor for gaskets and the like?

Thanks in advance - I've only just found this forum and have learnt a great deal already!

...just noticed this thread is from 2006 - is it still a hijacking or is it more of a reviving?!

Helicoil is good, an alternative is

 

 http://www.timesert.com

Thanks all. I'd seen the timeserts mentioned on various youtube vids as a better alternative to helicoils but an expensive kit to buy that I probably (hopefully!) wouldn't get the use out of.

I'll get myself some gaskets and hopefully get some time at the end of the week to have a nosey.

Radiator fan also needs replaced so I'm off to trawl the forum for some info on that. Looking forward to actually get to swing my leg over the thing at some point!

Cheers

Just discovered the sticky at the top of the GG forum. I have a rad fan from a Suzuki of some sort that looks like it will fit ok but I wasn't sure how to separate the old motor without destroying everything...seems like I have to do a bit of destruction after all!

I'll look into the cornwall boats tip if I have no joy with this one.

Great resource this forum!

Sorry - I meant the destruction of the motor through tapping/thumping the shaft out of the bearing. It's cooked anyway!