What would you do about this head bolt?

[El Pescador]

The head is stripped out and it's going to be impossible to drill. I can get a hacksaw blade in there, but I'm afraid of screwing up. Your suggestions are appreciated.

[Bixxer Bob]

Hard to tell from your pic but if you are trying to remove a stripped stud, you need a stud extractor.  They aren't expensive, like these:

http://www.ebay.co.uk/itm/Stud-Extractor-Remover-Set-6-8-10-12mm-manifold-exhaust-Stud-Extracting-Remover-/150999676976?pt=LH_DefaultDomain_3&hash=item2328483830

[iansoady]

I think he's talking about the one between the 2 ports with its head pointing upwards at about 30 degrees off the vertical. I don't think a hacksaw blade slot will be enough to tackle it. You may be able to MIG weld a nut on top - or even a socket head screw. Otherwise a Dremel with a cutting wheel to cut the top off? In either case I'd remove the exhaust studs first to get a bit of room.

Not a job I'd fancy myself.

[El Pescador]

I think he's talking about the one between the 2 ports with its head pointing upwards at about 30 degrees off the vertical. I don't think a hacksaw blade slot will be enough to tackle it. You may be able to MIG weld a nut on top - or even a socket head screw. Otherwise a Dremel with a cutting wheel to cut the top off? In either case I'd remove the exhaust studs first to get a bit of room.

Not a job I'd fancy myself.

That's the one. Sorry I'm working of my phone so post doesn't have a whole lot of information.  As you can sort of see, I already have a hacksaw blade in between the head and the block. My thought is, if I cut the bolt and remove the head, I'll have a lot more room to work with.

[London_Phil]

I would be VERY wary of putting a hacksaw there. You run a massive risk of damaging headgasket sealing surface, and when you install a new gasket, you need to put little crescent spacers at that point to prevent warping the head.  I would try to dremel the head of the bolt off, then once the head was off, it will probably come out under finger pressure. Good luck..

[Mustang]

how did the bolt head get stripped ?

I suggest using an easy out .

just use an extension on the drill bit .

my second bit of advice would be to buy some good quality torx bits so you don't strip any more bolt  heads .
they will prove handy upon reassembly .
and if you don't have a shop manual (preferably Triumph) GET ONE !

[El Pescador]

I would be VERY wary of putting a hacksaw there. You run a massive risk of damaging headgasket sealing surface, and when you install a new gasket, you need to put little crescent spacers at that point to prevent warping the head.  I would try to dremel the head of the bolt off, then once the head was off, it will probably come out under finger pressure. Good luck..

Thanks. I may try this. There isn't a lot of room to work.

[El Pescador]

how did the bolt head get stripped ?

I suggest using an easy out .

just use an extension on the drill bit .

my second bit of advice would be to buy some good quality torx bits so you don't strip any more bolt  heads .
they will prove handy upon reassembly .
and if you don't have a shop manual (preferably Triumph) GET ONE !

I think the last person in there may have stripped it for me. They also left out the spacers. I hope they're still available. No matter though, it's my problem to fix.

I would like to go the easy out route, but it's a weird angle. Any suggestions?

[Mustang]

I think the last person in there may have stripped it for me. They also left out the spacers. I hope they're still available. No matter though, it's my problem to fix.

I would like to go the easy out route, but it's a weird angle. Any suggestions?

sharp chisel and hammer , smack it the same direction you would unscrew it . works every time .
the spacer pcs. come with a new head gasket .
don't forget to reseal (with hylomar) the cylinder liners at the bases when you reassemble

edit : found some pics on the net explaining the chisel and hammer trick

[threepot]

I have tried Mustang chisel method with success in the past. Can you cut a slot across,and use a large flat blade screwdriver?

[El Pescador]

Success!!!  Mustang, you're the man!  It wasn't easy or pretty, but I got that beast out with your chisel method.  Thanks for all the suggestions.

[El Pescador]

The head is off. The pistons are pretty clean, as are the valves. Would y'all suggest any work other than resealing the sleeves and putting a new head gasket on?

Also, my head gasket did not come with any spacers for the two bolts in the front of the head.  Should I make some out of the old head gasket?

[Sin_Tiger]

Glad you got the right advice in a timely manner. Next time you're in the tool store, invest in a diamond point chisel, that works best where you can't get at an edge, a good Centre punch will also work in a pinch.

As you say and head work, then you'll be good to go.

[Henry James]

Not sure about everyone else...
I would clean the tops of the pistons, carefully, don't like carbon floating in my cylinders.
I would remove the sleeves, and carefully clean both mating surfaces, hylomar wants very clean surfaces.
Me, I would replace the rings, but that is a personal choice.
I would make sure the rings are rotated in the correct position before assembly.
Dry the cylinder area throughly, heat gun.
I am sure I forgot something....
I always say a prayer.

[97tiger885]

The head spacers are listed separately at BikeBandit under Engine & Exhaust,  Cylinder Head & Valves. 

Item 26:  spacer gasket cyl head, 3 cyl at US$1.49 each.

Part number 1378613.