Help with hose change, and botched screw in airbox

[TCFA]

Hi everyone

CBR600F is the bike. 2002 FI model (sometimes called F2, or F4i).

Trying to change the coolant hoses to a sparkly new silicon set. All drained and flushed without any problem. Some of the hoses easy enough. But trying to get to the hoses on the back of the engine block, man that is HARD on this bike!! Any tips??

Got them all off bar one, short fat pipe runs from low down back of block to water pump. Doesn't help that the jubilee clip is spun round so even harder to reach to get a screwdriver to. And getting everything back on will be hideous!

I had the tank right up but will remove it to try again (as am changing it anyway) so maybe getting those hoses out the way will give me a bit of room at the top. I tried to take airbox out (more below on that cockup .......) but realised it wouldn't give me much more room anyway. Unless I go further and take the injectors out too?? Is that the answer?

Any advice would be greatly appreciated.

Airbox - now I really botched this. What a muppet. Was unscrewing the funnels, one last screw would not budge, and I chomped the head up with my screw driver. The I tried to get it out with one of those drill bits that you set to anticlockwise and is supposed to grab the screw and extract it, but all I ended up with was a drilled out screw head and no way to undo it as the bit would bite and thread in.

Any tips on getting this out?? I really don't want to have to cart the bike to a garage (it's off the road, SORN, project/track bike) just to get a screw out, but it's not something I'm very good at it seems.

Thanks for your help as always

Cheers

T
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Then: Kawasaki ZZR250 > Suzuki Across 250 > Suzuki SV650 > Honda CB750
Now: Honda CBR600F and Triumph Tiger 800 XRT

[stinkwheel]

The screw will probably undo now if you remove the part and get mole grips on the stump. They aren't in tight.

You need JIS screwdrivers to undo them without burring the heads. There's one in the bike toolkit.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[TCFA]

thanks for the tip on the screwdrivers, good to know

I don't think I can remove the part though as that screw is captive in the funnel and passes through and holds the whole airbox to the engine.
____________________
Then: Kawasaki ZZR250 > Suzuki Across 250 > Suzuki SV650 > Honda CB750
Now: Honda CBR600F and Triumph Tiger 800 XRT

[stinkwheel]

But if you've drilled the head off, there's nothing holding it?
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[1198]

Can you heat the hose to make it more easy to work into place? Place it in hot water perhaps?

[droog]

I've got a CBR F4i and I recently took all this stuff off - I just took a look at the velocity stacks where you have the stuck screw.

Based on your description I'm assuming you have drilled a hole in the centre of the head but the head is still basically intact?

If that is the case I would do the following based on the tools I've got at my disposal before I started contemplating drilling it out.

Get a long centre punch and a stubby hammer (so you can be more precise) - put the punch on the outer edge of whatever is left of the screw head at 45 degrees and try and hit it so that it is going anti-clockwise - be very patient don't use too much force and take your time - tap tap tap etc - it should eventually start moving.

Put a light over it so you can see what you are doing - assuming you can get the head of the punch to dig into the edge of the screw head then it will start moving eventually.

[droog]

Regarding that hose at the back - yes you will need to take the throttle body off to access the hose.

You may know this already - but if not - have you got a very long phillips screwdriver? Because you will need this to reach the clips that secure the throttle body to the intake stubs.

The screwdriver pokes through holes on each side of the frame so you can reach the screws which tighten/untighten the clips for cylinders 2 and 3 - you can reach the clips for cylinders 1 and 4 with a normal length screwdriver (the holes in the frame were put there for exactly this purpose).

You don't have to worry about taking the throttle cables off - once you have loosened the clips just lift the throttle body off, move it forward and rest it on top of the valve cover.

You will then be able to access the rear hose.

[sickpup]

Most hose clips can be opened with a small socket from a 1/4" socket set. They are often either 5 or 6mm or older ones tend so be 1/4". Always replace with Stainless steel ones.

[TCFA]

[TCFA]

thanks for the tips Droog. Once I get the airbox off I'll get onto that. I have a set of Halfords advanced screwdrivers but none are extra long so I'll order one.
____________________
Then: Kawasaki ZZR250 > Suzuki Across 250 > Suzuki SV650 > Honda CB750
Now: Honda CBR600F and Triumph Tiger 800 XRT

[TCFA]

[Pete.]

7mm is the most popular size for hose clip worms. Bikes sometimes have 6mm. Over-size clips might be 8mm and you get the odd round head with a screwdriver slot. 1/4" I haven't seen one for a long, long time.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[TCFA]

oh my god. 3+ hours to remove that screw but I got there.

I couldn't drill the head fully off to lift the funnels (I think possibly my drill isn't making full power) and I wasn't successful with the centre punch technique (I didn't have a long one anyway) so I ended up having to break the funnels off so I'll need to replace them.

I tried getting pliers around the screw but ir wouldn't budge. tried getting a socket to grip on it but no. tried various bashing and swearing. eventually successful after cutting a slot deep through the head, jamming a 0.7 shim in, and gripping that with the pliers to release the screw. It came loose with a big snap so it was well and truly jammed in.

Next job tank off, then throttle bodies out, then I'll get those hoses done!!
____________________
Then: Kawasaki ZZR250 > Suzuki Across 250 > Suzuki SV650 > Honda CB750
Now: Honda CBR600F and Triumph Tiger 800 XRT

[TCFA]

[Easy-X]

One of those situations where you can't substitute mole grips with pliers. Not unless you spend your winters cracking walnuts by the fireside with your bare hands!
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Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[stinkwheel]

[droog]

[TCFA]