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Old July 14th, 2019, 03:46 PM   #1
Aodhfin
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Removing head cover

I'm trying to adjust the valves and am stuck removing the head cover. Have removed the coils and can _almost_ sneak the head cover off without doing anything else, but the coolant pipe is in the way. If the coil brackets could come off it would be no problem but they are _just_ in the way. Don't want to pull the coolant pipe off as I'm sure that will spill coolant all over the place. Should the cover come off as is with a fair amount of wiggling, or should I remove something else as well?
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Old July 14th, 2019, 03:57 PM   #2
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If I remember correctly there's a little metal hold-down tab on the metal pipe that comes upward out of the cylinder head (the coolant outflow at the back of the cylinder head cover). You have to loosen up the pipe and rotate the tab out of the way.
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Old July 14th, 2019, 04:01 PM   #3
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You can also drain some coolant at water-pump. Then pour it back in later.
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Old July 14th, 2019, 04:38 PM   #4
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Read through this section - https://faq.ninja250.org/wiki/How_do..._the_valves%3F

You need to drain some coolant and remove the pipe as noted.
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Old July 14th, 2019, 05:07 PM   #5
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Quote:
Originally Posted by DannoXYZ View Post
You can also drain some coolant at water-pump. Then pour it back in later.
That's what I ended up doing, not as painful as I had feared. Now I can replace that o-ring as well.
Thanks!
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Old July 15th, 2019, 06:34 AM   #6
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I never drain coolant, I just loosen up the radiator and remove the fan as well.
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Old July 21st, 2019, 03:44 PM   #7
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Thanks everyone. The pipe came out after I drained the coolant so it worked well. I also ended up pulling off the front fairing (which I was trying to avoid) as well as removing the radiator. Thought if I could just squeeze my hand in it would be fine. Ended up saving more time and effort by just taking things off and being done with it.
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Old July 21st, 2019, 07:14 PM   #8
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Hey good job! Sometimes, I just drop engine to do valve adjustment. Quicker than trying to move bazillion hoses, wires and stuff out of way!
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Old July 23rd, 2019, 09:07 AM   #9
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To make this easier in the future, you can also take off the upper engine mounts, drill the spot weld that holds on the coilpack bracket, and touch it all up with paint so it doesn't rust. Then you'll be able to get the radiator loosened up, coil packs removed, and valve cover snaked off the top of the engine without having to undo your engine mounts and dangle everything off the rear two mounts.
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Old July 23rd, 2019, 03:29 PM   #10
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Quote:
Originally Posted by choneofakind View Post
To make this easier in the future, you can also take off the upper engine mounts, drill the spot weld that holds on the coilpack bracket, and touch it all up with paint so it doesn't rust. Then you'll be able to get the radiator loosened up, coil packs removed, and valve cover snaked off the top of the engine without having to undo your engine mounts and dangle everything off the rear two mounts.
I donít bother with drilling out the coil pack spot welds, I unbolt the radiator and let it hang by the hoses and then remove the top engine mount brackets with the coils still attached. Plenty of room for big, meaty hands to get in there!
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Old July 25th, 2019, 07:29 PM   #11
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Quote:
Originally Posted by 59096 View Post
I donít bother with drilling out the coil pack spot welds, I unbolt the radiator and let it hang by the hoses and then remove the top engine mount brackets with the coils still attached. Plenty of room for big, meaty hands to get in there!
I started out doing it that way. It's easier and cleaner not to have to dangle the radiator.
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