Kawi2strokes.com Forum

I am tearing apart my H1F to identify and correct my shifting problems. I have read every thing I can find about removing the cylinder barrels. Haven't found the golden nugget yet. I have never seen barrels so difficult to unstick. And from other recent posts, I know I am not the only one facing this challenge. Next, I can't get the cases split. It looks like someone used sealant between the case halves. I have already broken one cylinder stud.

Anyway, all suggestions are welcome. Someone needs to make videos of how to disassemble a stubborn motor. I am considering all sorts of out-of-the-box ideas like shoving a bladder under the piston and down into the case and blowing it up, or expandable foam. There must be some novel ways to approach these issues.

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You are not old until you have more regrets than dreams! - John Barrymore (rephrased)

75 H1
78 CB400II Hawk
78 KE175

Are you sure all case nuts are removed.... under rubber mounts?

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Answers are here: http://kawatriple.com/

Yep. I think it is the sealant holding it together.

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You are not old until you have more regrets than dreams! - John Barrymore (rephrased)

75 H1
78 CB400II Hawk
78 KE175

To help loosen the jugs for removal, heat and a good lube usually works. (eventually)
What is it some fellas mix with ATF?
Acetone or something? Supposed to be a great penetrating mix.
As for the cases, IF you removed the oil scavenger and as Dale mentioned you know you got all the nuts off the lower end,
the cases should come right apart with a few blows of a rubber mallet.
Good luck with it.

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Bad decisions make the best stories.

Pictures always help and I know on my H2 I have small nuts as well as larger.

Thanks for the replies. After soaking liquid wrench down the stud holes for several days, two cylinder barrels came loose. The third is still stuck. I am going to try acetone next (as someone suggested) and if that does not help it break loose, I think I will wrap some dry ice around the base of the cylinder base and see if that works. After I get the cylinder off, then I will go back to splitting the cases. I will try to get a picture of the clear-hard sealant at the case seam (resembles super glue). I really do have all of the nuts off. It is pretty easy to find them all when you remove the rubber mounts (which was something I did before removing any nuts because I wanted to loosen them a little at a time). I said it before, of all the bikes I have worked on, I have never experienced this before. Keeps things interesting! Whoo-hoo!

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You are not old until you have more regrets than dreams! - John Barrymore (rephrased)

75 H1
78 CB400II Hawk
78 KE175

I wonder if "evapo rust" would work. It seems to remove rust quite well and is relatively benign otherwise.

When I have a stubborn set of cases I use a brake spreader between the lugs in the back of the cases to get them started.


http://www.amazon.com/OTC-7034-Disc-Brake-Spreader/dp/B0002SQUHW/ref=sr_1_2/182-6293757-7888142?ie=UTF8&qid=1416109582&sr=8-2&keywords=brake+pad+spreader+tool

Thanks Falconman. That looks like a good option.

_________________
You are not old until you have more regrets than dreams! - John Barrymore (rephrased)

75 H1
78 CB400II Hawk
78 KE175

To make sure you have all the nuts removed you should have 12 10mm nuts and 15 6mm nuts removed from the casings

Gary T

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Wine for my men we ride at dawn