Cylinder Removal - Request For Comment

[gazza]

Hi All,

First time post with a dumb question which may've been covered already..apologies in advance..

I'm currently dismantling a 2000 Bullet with a blown big end, to replace the crank, mains, rod etc. I'm trying to remove as many large components as possible before dropping the crankcase from the frame. The head is off, but I'm having trouble removing the jug. Am I right in thinking that the cylinder is held fast between the two halves of the crankcase? I haven't yet loosened the crankcase bolts.

The plan is to initially reassemble with a beefed-up bottom end (blueprinted crank, good mains, roller big end, Carillo rod etc.) but standard jug and head (due bike fund limit), just to get back on the road as soon as possible.

I'd like to know the secret of swapping the cylinder on the assembled crankcase, so I have the future option of upgrading to oversize piston/alloy jug and improved head without having to go for the full case split.

Is such a thing even possible? Thanks for any comments.

[The Garbone]

Welcome to the forum.

Once you pull the head the only thing holding the jug on is the one little stud above the tappet access plate.   Take that little nut off and the jug should lift right up off the piston.

You can swap the jug and piston without having to touch the crankcase.  Its all pretty easy.

One thing I did when I pulled my head off my 07 was replace the stock studs with a better grade set purchased from McMasters.   They will stretch less when torquing to spec.  The stockers work but I just get stressed out when it takes a relatively large amount of snugging to get the torque value you want, I worry about stripping out the aluminium.

[gazza]

Thanks Garb.,

I spotted that little bolt, but the barrel remains stuck fast. Still trying..

[The Garbone]

I guess the bottom gasket between the barrel and crankcase can stick a bit,  it should lift right up though.  With the 2 engines I have pulled the barrel on it has not been an issue.  Usually its the head that is tougher to pull.

[Eamon]

I guess the bottom gasket between the barrel and crankcase can stick a bit,  it should lift right up though.  With the 2 engines I have pulled the barrel on it has not been an issue.  Usually its the head that is tougher to pull.

That was my experience as well.

[gazza]

Its off! Just needed a smart blow via a wooden mandrel to overcome the sticky gasket. Thanks all.

[Ice]

 Glads you got it apart.
Keep us posted