Stuck Engine Bolt

[Chriss]

Hi all,

I've got a stuck engine bolt on my K3 GS500e. The bolt itself is siezed. I can get the nut off, but when I tried to remove the bolt, the head just sheered off.

Has anyone got any ideas as to how I can remove the rest of this bolt, short of dropping the engine out and hitting it with a hammer?

Thanks

https://img847.imageshack.us/img847/2504/imag0810g.jpg
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TheShaggyDA: I've got 3 or 4 pairs that predate my wife, so at least 11.5 years old.

[MarJay]

[P.addy]

Support the engine with a jack and try to punch it out with a hammer and your least fave screwdriver?

My dad has an old rasp file with a broken end for jobs like this


Upon reading MarJays post... does the screw thread through the engine or does the nut just do up on the threaded area? I cant recall on my GS500 whether it was a long threaded bolt...

[Pete.]

Had to remove a Hornet one like this a couple of weeks ago. Only way to shift it was drill an 8mm hole down the middle.
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a.k.a 'Geri'

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

[DrDonnyBrago]

[Chriss]

I put a jack under the engine anyway to try and make it easier to get the bolt off. The jack is still there.

Paddy, here's a picture of the fische, which may answer you question, since I didn't understand it

https://img856.imageshack.us/img856/3528/gs500enginebolt.png

Upon looking again, the bolt's sheered half way through the frame, so I cannot get at it to dremmel and the engine wouldn't drop anyway.

Have tried hitting with a hammer and screw drive with no joy, literally. My poor hand.

Pete. When you say drill the engine bolt, I'd be worried about not getting it perfect and making the hole oval. Also, it'd have to be a hell of a size drill bit to go all the way through.
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TheShaggyDA: I've got 3 or 4 pairs that predate my wife, so at least 11.5 years old.

[P.addy]

Bigger hammer Park the bike against a wall and jack the engine up a little. Dont worry about the bike falling as its against the wall, just fuck that bolt and give him some serious stick

[Chriss]

[P.addy]

[stinkwheel]

Looks bent to me from your picture.

You might be able to get a junior hacksaw between the engine lug and the spacer (part #28) and cut the bolt into three bits. Then you're just left with the bit in the engine lug (which is probably where it's seized).

A 50:50 mix of ATF and paraffin makes a good penetrating fluid.

A proper drift or a long bolt is better than a screwdriver. Make sure the face of it is filed perfectly square so you can do maximum whaling.

Had a similar problem with my mainstand bolt on the VFR and landed up drilling the bugger out in the end.
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“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.

[Kickstart]

Hi

To add to the suggestions above, if the nut is in reasonable condition put it back on (possibly with a washer or 2 underneath as spacers) and tighten it up hard. Hopefully there is enough thread for it to pull the bolt across slightly. However it might well just strip the thread on the nut.

Probably worth using decent penetrating fluid (ie, not WD40), plus heat (blowtorch) and cold (freeze spray) to try and free things off a bit first.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Chriss]

Great. My super reliable transport to get me to university is fucked.

I've tried drilling it, but it's made a small indentation where the drill is now it just spins, not going any deeper.

I've tried hacksawing it, but whatever cheap crap this is made from is pretty damn tough, breaking five hacksaw blades. Probably got more to do with the stupid angle I'm working at though.

Used Plus Gas, Freeze and Release and a blow torch, which set the bike alight for a second, which made me laugh, until it stopped burning.

Can I just add, when Hyosung claim they make parts for Suzuki, I believe them

What's caused all this is moving engine bars from a 1994 GS500 onto a 2003 GS500. The 1994 saw more of winter than the 2003 one, but any such problems? Oh no!

Anyone near Harrow fix this for me?
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TheShaggyDA: I've got 3 or 4 pairs that predate my wife, so at least 11.5 years old.

[DrDonnyBrago]

[Chriss]

This is the exact drill bit I bought and these are the hacksaw blades that I have.

I've no idea as to what either are made of.
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TheShaggyDA: I've got 3 or 4 pairs that predate my wife, so at least 11.5 years old.

[DrDonnyBrago]

[tatters]

Is the bike rideable? and do you have a replacment bolt?

If so let me know and bring it over to my workshop and l,ll get it out, owe you a favour for getting that KLR part for me.
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Past:NRG50,AF1125(x2),NSR125RR,ZZR250,CX500,VFR400,KR1S,ZZR600(x2),CB400N,YZF1000(x2),KH125,Z200,FX400R,CBR954RR(x2)GPZ500S,GT550,VFR750F(x2),RD350N,XR650R,CBR600F,CB250,KDX250,YZF750R,CRM250,400EXC,KLR650,TTR600RE,DR350S,R100GSPD,RGV250,VMAX1200,DL650,KZ750 Present:G650XC,C12,CRF450X,1190ADV

[Ed Case]

Sadly this is a very common problem with Oriental bikes, questionable steel and shite zinc-based alloy + a few British winters and this is what you get. The only real answer is get the engine out and get drilling. Avoid brute force if you can as it's not unknown for a chunk of crankcase to come flying off and then you're totally phukt. A bloke I knew knocked the complete front engine mount plus a big lump of crankcase off a 250RS. Basically, cheap materials good enough for the expected 'life' of the bike, which is a lot shorter than you'd imagine, and no longer.

[el_oso]

i suspect that hitting it with a hammer will not work. use a decent drill bit and drill very slowly spraying WD-40 on it every 10/20 seconds. using a fluid to cool and lubricate the metal is essential. if you don't have any WD-40, get some, will make your job 100x easier.
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Duke 390
Previous: '05 XR125L | '96 XJ600S Diversion |'05 Suzuki GSXR1000 | '05 Honda CBR125-R | '97 YZF 600R Thundercat | '11 Honda CBR250
Car: Jeep Wrangler 4.0L

[Chriss]

[P.addy]

[Chriss]

[P.addy]

[Chriss]

[Grubby]

Use plus gas, lots of it & find someone like me works in the aerospace industry who has access to a 7X rivet gun. It'll scare the bolt out just by walking towards the bike with it.
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I am me & you are he & we are all together. See how they run like pigs from a gun!

[MarJay]

Where the bolt is now its not going to go anywhere by riding the bike. Riding the bike won't do any harm... Just take it easy.
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F; Cheap project: CBR900RR FireBlade
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.