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Removing aluminum cam plugs 09 Sep 2018 15:37 #790607

  • loneagle
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I installed some aluminum cam plugs when I rebuilt my engine and now I have one that leaks. I used Three Bond sealant when I installed, I must have not used enough. I'm concerned because the cam plugs were a tight fit and had to be lightly tapped in. I don't want to break the cylinder head trying to remove the plug. If anyone has any suggestions, please advise and thank you!
'78 Kawasaki KZ 1000
'02 Harley FXDWG
'16 Harley Street Glide

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Removing aluminum cam plugs 09 Sep 2018 16:13 #790614

  • daveo
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I have one cam-end plug seam that leaks a tiny amount of oil too, and used Three Bond 1211 on mine.
Thinking I'll snug-fit a drill bit shaft in the plug-hole, and leverage it to rotate all the plugs free without much effort. Then clean them all up and do a better job sealing them in next time once the head is installed.

:)
1982 KZ1100-A2

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Removing aluminum cam plugs 09 Sep 2018 16:22 #790616

  • Street Fighter LTD
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Per the OPs information 1978 KZ 1000
No bolt holes in cam end plugs
You should be able to just tap them out
Use a small piece of hardwood against the plug to protect the aluminum from being marred or distorted
I use Yamabond on mine with good results
Dave

Original owner 78 1000 LTD
Mr Turbo Race Kit, MTC 1075 Turbo pistons by PitStop Performance , Falicon Ultra Lite Super Crank, APE everything. Les Holt @ PDM's Billet Goodies . Frame by Chuck Kurzawa @ Logghe Chassis . Deep sump 5qt oil pan. RIP Bill Hahn
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Removing aluminum cam plugs 09 Sep 2018 17:38 #790621

  • daveo
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Often wondered about eliminating the hole in the later models with permanently mounted aluminum plugs, Would be nice to get rid of those four seemingly useless bolts.
1982 KZ1100-A2

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Removing aluminum cam plugs 09 Sep 2018 19:10 #790626

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Thanks for the advice guys! I'm going to give it a go with the hardwood dowel. It may be a lot easier than I'm anticipating. I hate oil leaks, especially on a freshly rebuilt engine!
'78 Kawasaki KZ 1000
'02 Harley FXDWG
'16 Harley Street Glide

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