I have a GSXR250 here for a revival - bought by a mate, it's pretty rough around the edges and needs a thorough going over. Including the valve clearances - but the cover is frozen on. It's the type with two water outlets up through the cover - and I'm pretty sure they've corroded into the head, preventing the cover coming off. My next move is heat onto the adjacent head casting to try and move the steel pipework. After that I may put a tap down the tubes so as to insert a couple of bolts to pull up on... Has anyone struck this problem before - and found a simple solution ?
Have you got a picture? I don't think they would be water outlets, not on a cam cover. They might be PCV hoses. If you have all the bolts out, give it a few light taps on either side with a mallet
Yeh the Bandit is the same, there are 3 hoses to the thermostat - two of those go into these ports. They actually stick up through the cover, so really you should be able to lever the cover up and it should slide over these ports. If you've got rust around them it's a bit trickier, maybe some heat would help but I'd be tapping them in places with mallet like Linkin suggested first - just to try and crack the attachment. Here's a bad photo I took of the bandit connections, one on the left and one on the right. This is what it looks like with the cover removed.
Well, if they're permanent fixtures in the head and the cover comes off over them, that's a shiteload easier... The only pic I could find of a cover appeared to have the tubes attatched. Thanks gents.
Yeh it's a bit of a head scratcher... maybe there was no room to pipe it to the cam chain tensioner side of the engine like the Yamaha's do...?
It's actually not uncommon for the water offtakes to be straight up off the head - but not usually through a cover too. I note that these things have the waterpump bleed screw same as the 400 Impulse - but this time hidden under the sprocket cover. The Impulse has a rep for running hot - as apparently was this pos - if the pump isn't bled that's what happens. For your amusement - it had CR7 short reach plugs fitted, nearly new too.
Well it's off - and the gasket is even reusable. Heatgun on the area around the tubes and douse with penetrating oil. Then it was lever the cover up quietly, trying not to damage the edges... One tube was worse than the other - obviously that side hose had dribbled down. Everything will be cleaned up, new O rings and it'll go together with a wipe of anti-seize...
Good one. Think I got mine off by spraying some WD40 on the rusty water pipe and putting a block of wood against the lip of the head and banging away with a rubber mallet.
