need help with 603 head
 

ok, so i blew a head gasket, don't know if i do indeed have a cracked head, so i proceeded with the head removal...

i got as far as removing all relevant obstacles, i just can't remove the dang guide rail pins!, i managed to strip and crack the upper pin, so i drilled a hole on the other side and hammered it out. I also managed to strip the lower pin but i also managed to eek it out about 1mm using the washer method. anyway, i tried doing the same thing by drilling and hammering but the dang pin just won't budge, i'm not sure if i've drilled enough, so.....

how long is the lower pin, i'm asking coz i want to know how far in i should drill.

If ever i don't get the pin to budge, my last resort would be to cut the chain and just put a new link after. any suggestions? i really really have to remove the head to get it checked. Thanks guys!

I think before you started drilling you should have done the washer method. Usually, if it wants to strip out then you don't have the bolt in the pin far enough.

Thanks
David

i tried the washer method with the lower pin but stripped out also, i didn't realize that the threads didn't go all the way to the end of the pin, coz there was blockage about past an inch in. if i knew there was blockage i wouldn't have threaded the bolt in deep.

anyway, that's that, so do i just cut the chain? if i could save the chain that would be great. so how deep does the lower pin go through the aluminum?

or how long is the lower pin?

I think if memory recalls, they are the same length. Confirm it by part number, if upper and lower have the same part #, obviously they are the same.

If you end up removing a chain link, make sure you don't drop it, and you might want to order new chain guides while your at it, and maybe a new chain as well. Take it out and measure the slack in it. I think I read 4 or 5 mm of slack is the limit, but check the archives here to confirm that.

Do you know where the cracks usually are? Even if you don't see any, you might want to have it pressure tested anyway.

yup. i'll definitely have it pressure tested, thanks