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Thread: Sad day... just found a crack in my Cylinder head...

  1. #1
    Member Richie-Rich's Avatar
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    Sad day... just found a crack in my Cylinder head...

    Crashed at PPIR last MRA event in the dirt... Went to go ride my bike after finally fixing my shift lever and exhaust is coming out the front of my bike. Left side of my cylinder head is cracked... Anyone ever replace one of these things? What am in in for...

    Last edited by Richie-Rich; Sat Aug 30th, 2014 at 08:17 PM.
    08 Kawi Green Ninja ZX-6R

  2. #2
    Senior Member Wrider's Avatar
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    Re: Sad day... just found a crack in my Cylinder head...

    That's quite a bit of work. You've gotta drop the motor, pull the valve cover, pull the cams, pull the head, then re-install it all. If I had a full shop with full tools to do it I'd say that's a solid 8-10 hours of work with no breaks. That also means new coolant, new oil, new crush washers for the exhaust, new head and valve cover gaskets, re-timing the cams, might as well do a valve job on the new head to make sure everything is good and in spec, get the new head's cylinders honed, new rings for the pistons.
    Sorry to hear about the misfortune man. Cracked cylinder heads suck.
    Have owned: '01 Volusia
    Currently own: '05 Z750S

  3. #3
    Member Richie-Rich's Avatar
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    Re: Sad day... just found a crack in my Cylinder head...

    Damn...sounds...fun... The cylinder head alone is going to run me $200-900 depending on the condition of it and if valves are included. I need new clutch disk also so I think this will be a winter long project. Thanks for giving me an idea of what I am in for.
    08 Kawi Green Ninja ZX-6R

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    Senior Member Wrider's Avatar
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    Re: Sad day... just found a crack in my Cylinder head...

    FWIW it's seriously doubtful your valves have been damaged, so you can always swap over valves (just make sure to get new valve guide seals). I'm sure someone around here has a valve tool so you don't have to buy one to swap them out.
    Have owned: '01 Volusia
    Currently own: '05 Z750S

  5. #5
    Senior Member FZRguy's Avatar
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    Re: Sad day... just found a crack in my Cylinder head...

    I think it's easy so long as you have plenty of time and $. Pull your head and take it and the new one to a machine shop for the prep work. Mostly just a parts collection project, and don't pull the cylinder unless you want to double time and expense.
    John
    KTM Duke 690

  6. #6
    Member milehizx6r's Avatar
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    Re: Sad day... just found a crack in my Cylinder head...

    Quote Originally Posted by FZRguy View Post
    I think it's easy so long as you have plenty of time and $. Pull your head and take it and the new one to a machine shop for the prep work. Mostly just a parts collection project, and don't pull the cylinder unless you want to double time and expense.
    Neil is right, get the new head and send it to a machine shop to mill the head and check valves and guides. It is a very long process and money is a concern as well. The parts and gaskets will add up.

  7. #7
    Member Richie-Rich's Avatar
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    Re: Sad day... just found a crack in my Cylinder head...

    Thanks for all the input. I have about 23k miles on her, is there anything else you would recommend on cleaning, replacing while I have the bike torn apart this much? I am going to replace the clutch disk and maybe basket I think in the process of doing this replacement. Also am turning her into a track only bike so I will be putting on my race body work and safety wiring everything.
    08 Kawi Green Ninja ZX-6R

  8. #8
    Senior Member Wrider's Avatar
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    Re: Sad day... just found a crack in my Cylinder head...

    If you're going that far, take a good solid look at everything. Check the play in the connecting rods at the big and little ends, take a glance into the crankcase to see how it's looking. Might as well take a good hard look at your transmission while everything is apart.
    Have owned: '01 Volusia
    Currently own: '05 Z750S

  9. #9
    Senior Member FZRguy's Avatar
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    Re: Sad day... just found a crack in my Cylinder head...

    Manual adjust CCT.
    John
    KTM Duke 690

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