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Re: tl head removal
You can actually tilt the engine towards the front tire -rotating on the rear mount if yu hve teh front mounts removed. At the apoint the head can go all the way until it touches the tire. Somewhere in between you may have enough room to remove the head.
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1. Remove seat.
To protect against accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.
2. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.
3. Remove the primary chaincase cover.
4. Bend tab on lockplate away from head of jackshaft bolt.
5. Holding pinion gear to prevent rotation, remove the jackshaft bolt with lockplate and thrust washer.
6. From right side of motorcycle, remove starter front mounting screw with lockwasher. Remove rear mounting screw with lockwasher (and battery negative cable ring terminal). Remove Keps nut from stud of bracket tab and remove exhaust support bracket.
7. Pull back rubber boot and remove flange nut from starter post. Remove main power and battery positive cable ring terminals from starter post.
8. Depress external latch and pull solenoid connector from top of starter housing.
9. Locate oil filler plug/dipstick on right side of motorcycle at top of transmission case. To remove the oil filler plug, pull steadily while moving plug back and forth.
10. Remove the starter from the right side of the motorcycle, carefully sliding it through the space between the exhaust pipe and side cover.
NOTE: If necessary, remove Allen screw and decorative chrome
cover to facilitate starter removal.
11. Remove the coupling from the starter motor output shaft, if necessary.
The motor mounts at 4 points-cylinder head, 2 under the front of the motor, and the swingarm pivot bolt. In order remove- seat,tank,rear subframe,exhaust.Remove the motor mount at the rear of the head, leave the throttle cables on the carb, unplug the wires to the TPS and remove the carb.Bag it and tie it up out of the way. Remove top bolt of rear shock and the swingarm bolt, pull the entire swingarm and suspension back as far as you can-you'll need the room to back the motor up a little to get it out of the frame. Unplug the ignition wires, and remove the last 2 mounting bolts from the front of the motor thru the frame. from the left side of the bike, back the motor up and rotate the front toward you and it comes right out. Actually took a break from installing a fresh Honda 250 R motor to write you this tip! Good luck!
you will have to remove the exhaust from the head
if there is any of the stud left protruding from the head there is a tool that you can buy from your automotive spare parts dealer to remove the remaining stud
If no part of the stud is protruding you will have to drill a hole in the centre of the stud and use an easy-out to remove it, use some penetrating oil first to loosen any corrosion etc
Spray the bolts with WD40 several times over a two hour period. Use an impact driver and metric socket to loosen the bolts. The shock from the driver is your best chance to loosen the bolts. In the event a bolt or two does break, you should cut the bolt flush with the head, use a carefully placed center punch to center the bit, then drill the center of the bolt with a 1/16" bit. Then drill with a 1/8" bit and try a screw extractor to remove the remains. If still unable to remove the screws, you might want to contact a machine shop.
Take out the gas-tank, exhaust manifold, carb, the head-cover. Then take ouf the head. It would be better getting the shop manual, because the head bolts must be removed and tightened in proper sequence.
Sooner or later you will have no choice. The exhaust bolts must go because you need to pull the head for a valve job or gear box repair or whatever. Just as well do it now since the bolts will only get worse with time. Three options listed below >
The bolts come out okay and you install new bolts.
They break and you have a machine shop drill them out and tap new threads just a bit larger (and stronger).
Get a replacement head off the web >Google " motorcycle salvage yamaha "
You win no matter what happens. The dreaded problem is history and should not bother you again.
The sad fact is, you will probably be etter off removing the head and having the busted bolt removed and repaired, either by you or a machine shop. You have limited room, a ruined, hardned extractor in there.... going any farther with it in place will most likely F-it up more.
I wouldn't run it like that until you get those bolt holes cleaned out. The exhaust gases will leak out and burn/melt stuff nearby and you run the risk of scorching an exhaust valve requiring a head-job. And a head-job isn't as much fun as it sounds like it would be.,,