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Old 04-08-2015, 08:06 PM   #1
foxfire OP
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Is my cylinder head repairable?

Went to check the valves on my gas gas fse because it wasn't starting, and noticed the exhaust cam journal had worn into the head a tad. It's not excessively loose, just some small ridges and some aluminum transfer on the shaft.

I'm wondering if this is repairable, and if it's worth it. Used heads are pretty rare, otherwise I'd just replace it...but I'm not about to drop a huge chunk of cash into it either.

Is this a fairly common/inexpensive repair?
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Old 04-08-2015, 08:21 PM   #2
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Saw something like that on a Kawi head. You have to start working on where the aluminum transfer came from. If the journal, WHY? Could it have been pumped there by a banjo fitting (if equipped)?
Unfamiliar with your head so, that's all I can offer.
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Old 04-08-2015, 08:26 PM   #3
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Pics would be helpful. Some things can be fixed, others dealt with, still others are hopeless.
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Old 04-08-2015, 08:30 PM   #4
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got a pic? if you aren't panicking about what you see.... I'm guessing it can probably be cleaned up. also... how about the clearance? you can go to the auto parts store and get Plastigage for a couple bucks.... that will tell the real story

a transfer of metal between parts is "galling"... in this case, generally due to loss of oil pressure
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Old 04-08-2015, 08:34 PM   #5
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Galling...that's the word I was trying to come up with. For reference, this is very similar to a drz400 head. I have some pics somewhere, give me a minute...
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Old 04-08-2015, 08:39 PM   #6
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Between the valves is the area I'm concerned about.
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Old 04-09-2015, 04:31 AM   #7
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Contact Mike at Engine Dynamics.

Engine Dynamics LLC
2040 Petaluma Blvd. North
Petaluma Ca 94952
Phone: 707.763.7519


http://enginedynamics.com/index.html
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Old 04-09-2015, 10:44 AM   #8
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clean it up and check the clearance with plastigage. if the clearance is still in limits you run it. if it's out then decide how good of a fix you need and how much you want to spend. the real fix is to mill the mating surfaces on the journal & then re-bore on size, but I have salvaged heads like that with a couple hours of hand work lapping. wouldn't race it but fine as a runner.

what does the cap look like?
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Old 04-09-2015, 12:33 PM   #9
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Cap looks pretty good...better than the bottom. If you could, please spell it out for me like I'm not an engine builder...cause I'm certainly not. By clean it up, do you mean the bearing surface, the cam, both? What would be good to use for getting the aluminium off the cam shaft? And then polish up the bearing surface, or leave as it so as not to loosen the tolerances. And what kind of tolerance would be acceptable?
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Old 04-09-2015, 12:56 PM   #10
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See post #7.
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Old 04-09-2015, 01:10 PM   #11
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Quote:
Originally Posted by mcma111 View Post
See post #7.
Haha, yeah...if it comes to that, I will. But my moto budget is darn tight, and if I can get this done myself, that would be ideal.

Really, if it ends up being more than a $200 or so fix, I'll likely be forced to part it out.
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Old 04-09-2015, 01:57 PM   #12
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When was the last time the oil was changed?
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Old 04-09-2015, 04:01 PM   #13
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It had maybe 40mi on the last change. Honestly, oil changes on this thing are a pain...putting the recommended amount in always meant some ended up in the airbox. Never did find a happy medium. Oil was dumped before digging into the head, and it didn't seem like the 1200ml that should be there came out. On a positive, it wasn't the least bit sparkly.
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Old 04-09-2015, 05:00 PM   #14
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One way to get alunymoon off of metal is acid. This is a common practice for those running two-strokes when seizures happen.

It's used on cast and plated cylinders. I'm not sure how it will work for your part though. I'm thinking hardened steel should be ok but don't take my word for it.

Dilute some muriatic acid, use a wooden stick and dab it repeatedly on the aluminum and let it eat it off. Ventilation is a good idea. Rinse, then clean with soap and water.

I can have some acid if you want some.
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Old 04-09-2015, 08:51 PM   #15
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Went out tonight and got a better look. This isn't gonna be DIY. I bolted it back in and there's a LOT of play on that end.

I think I'll be parting the poor girl out soon...not really worth investing any more $'s.

Appreciate all the insight though, this has been a bit of a learning experience for me.
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