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Old 08-12-2014, 03:02 AM   #1
panhead_pete OP
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Before I break something - how does ignition cover on 800XC come off

Could someone be so kind to tell me how to get the cover over the ignition barrel on my 800XC come off. Faaaaaarking thing should just come off no? Got the two bolts out but it seems to be hanging up on something. Am I missing another fasterner?

panhead_pete screwed with this post 08-12-2014 at 03:33 AM
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Old 08-12-2014, 03:52 AM   #2
marlboroughlad
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the cover should come off pete, the ignition barrel has 2 shear bolts that need drilling. according to the manual.

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Old 08-12-2014, 03:57 AM   #3
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Thanks! Great pic. I had a manual sent to me but it's up at wk Doh....

All good now, time to install the new dampner.

Once I drill the tops off those bolts do they just come out?
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Old 08-12-2014, 04:04 AM   #4
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never tried it pete dunno. i guess so.
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Old 08-12-2014, 04:17 AM   #5
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Well once the head is drilled out / off and then there is no tension the bolts should unscrew easy by hand... unless Loctite has been used, then some pointy nose vice grips or stud extractor may be required ?

G
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Old 08-12-2014, 04:20 AM   #6
panhead_pete OP
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Apologies for another dumb question but am I drilling out just the raised centre of the sheared bolt (inner circle in the pic above) or the entire lot? Its a bitch to drill as the centre is proud of the rest.
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Old 08-12-2014, 04:30 AM   #7
Pete640
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Its a security bolt that isn't meant to be removed
Yes. Punch the ctr and use a 3mm drill to start a pilot hole. If u have a set of easy outs (screw removers) you can drill the appropriate size hole and you may be able to back the bolt out. If not use a 10mm bit to cut the head of the bolt off, the barrel will be able to come off from there
Use vice grips to remove the bolt and then replace once you have the damper buttoned up!!
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Old 08-12-2014, 04:34 AM   #8
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It would most likely be a 6 or 8mm thread underneath.
Centre punch it first and start with a 2 or 3mm bit down to a bit more than the depth of the head then work up in drill sizes until the head falls off.
Much the same as above.

Portly screwed with this post 08-12-2014 at 04:37 AM Reason: addition
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Old 08-12-2014, 04:51 AM   #9
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Thanks Pete and Portly, just did that and it works a treat. Now to move to fitting the dampner. It was suppose to come with instructions but they didn't get in the box. Didnt help two bolts weren't in the box, luckliy I bought a second one to be fitted to another bike and the appropriate bolts were in the second kit. Looks like it will all bolt up tomorrow. Really appreciate all the help!

panhead_pete screwed with this post 08-12-2014 at 05:46 AM
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Old 08-12-2014, 01:49 PM   #10
'Pirate'
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Can I chime in with a (slightly off topic) question?

Sorry for the hijack P_P. This won't take long.....

Without turning the question into a "which tyre/oil/fuel" question, I really want to pick up a proper service manual.
What is everyone using and where is the best place to pick one up?
Am thinking like what Marlboroughlad has in the pic. Was going to get one off EBay, but are there better options? I don't intend rebuilding the bike, but do like to have access to all the info

Thanks in advance, Pete.
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Old 08-12-2014, 02:09 PM   #11
marlboroughlad
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$51 manual wizard, ebay
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Old 08-12-2014, 03:30 PM   #12
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Quote:
Originally Posted by 'Pirate' View Post
Sorry for the hijack P_P. This won't take long.....

Without turning the question into a "which tyre/oil/fuel" question, I really want to pick up a proper service manual.
What is everyone using and where is the best place to pick one up?
Am thinking like what Marlboroughlad has in the pic. Was going to get one off EBay, but are there better options? I don't intend rebuilding the bike, but do like to have access to all the info

Thanks in advance, Pete.
Ask Panhead Pete for a copy Pete, I sent him a DVD with 800XC, Tenere 660Z, DRZ400 and DR650. Handy little things.

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Old 08-12-2014, 03:50 PM   #13
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Yep happy to pass on the love next week when I get back to work - where my copy is.
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Old 08-12-2014, 06:45 PM   #14
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You're an ideas man Pete.

This would be a great sticky thread if it hasn't been done already.

Now... How do I get next week's winning lotto numbers?

Anybody?
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Old 08-12-2014, 08:10 PM   #15
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Originally Posted by Strummer View Post

Now... How do I get next week's winning lotto numbers?

Anybody?
They're in here,

1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21
22 23 24 25 26 27 28
29 30 31 32 33 34 35
36 37 38 39 40 41 42
43 44 45 46 47 48 49
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