NSR 125 R Cooling system problem

[bikenut]

Pic...
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nuts about bikes

[david451]

[bikenut]

Barsalona ?

Sorry, my bad...

The mushroom fell out if it's hole in the clutch cover.....

Tried to post picture, no joy...

Pm me your email as it's easy to send pictures that way...

Try to get access to a mig welder.

Make a large washer from 1mm thick steel to protect the casing etc..

Drill a 6mm hole thru the washer so it fits over the bolt remains...

Make sure the washer is not too big, it must be able to rotate...

Remove delicate electronics from the bike..


Mig welder the washer to the bolt remains...

Grind to a taper a sacrificial bolt and migged weld to bolt remains....

You may have to protect further using damp rags stuffed into the sheared bolt area ....

Be aware of fire risk so TANK OFF etc..

I was tasked with removing a 3mm sheared off screw in a carb. It was just proud of the alloy carb body. I made the protective was from 18 gauge steel off cut. Drilled hole. Placed over Sheared of screw remains and welded to screw remains. Prepared sacraficial bolt and welded.

Allowed to cool.

Heated carb alloy to expand it a but, gay predators and a "please God" the little 3mm illigitamate unscrewed.
No carb or thread/hole damage.

E
Pm me so I can email picture....
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nuts about bikes

[david451]

Nope, not barcelona. There is a google maps link in this tread, since Pete himself wanted to fix the broken bolt but i told him we are a few milles away... its south east.

About the pic, short tutorial:

1- Click on "add attachment"
2- Click on "select file"
3- Finally click on "upload attachment" to finish the process.

[bikenut]

The bolt may have been corroded in.....lube is always good as is gentle back and forth bolt rotation.

Drilling and an easy out may make things worse for you, I know mig method works, just see the picture of the carb screw.....

Pm me your email...
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nuts about bikes

[bikenut]

David, you have a mig welder ?

Tried posting a picture, no joy, but will try again...mobile phone....
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nuts about bikes

[david451]

[bikenut]

No, doesn't want to work today....

Email method works easy...


Mig method works....use the method lots of times, screws, bolts, bleed nipples.....etc., etc., Etc.
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nuts about bikes

[bikenut]

Picture insertion should work, posted pictures of the pc50 moped in the for sale section, internet been a pita all day, probably cos of the sunshine today, it's normally due to all the dam rain !
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nuts about bikes

[david451]

okay i found it, its looks, as you said, as the part nº12 of the clutch schematics. Cool.

Now ill just wait for the extractor pieces to come. Ill post the results, either bad or good. Lets hope for the best

[david451]

Job done! Gotta say that it was way easier than i expected.

I just applied some oil between 10 mins intervals. Then some soft hits in the case with a plastic hammer.

Then applied the drill counter clockwise. The broken bolt would eventually turn a little from time to time. When about 2-3mm were out i was able to take it out with my own fingers

All things said, the extractor pieces i bough made no difference at all. They were only 9€ so not a big deal anyway.

Now ill wait for the new bolt to come, put it all together, and check if the very first problem of coolant is solved. Cheers.

[bikenut]

Glad you got it out ok, but what made the bolt lock enough to shear the bolt I wonder...

Clean the thread carefully...

When it's together, leave the thermostat out initially to check water pump actually pumps the coolant.

With a full system and rad cap off, rev engine slightly and coolant level should appear to drop slightly, then come back to level when throttle closed.

Check for air lock/bubbles etc...

When happy, thermostat in with corrosion inhibitor.
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nuts about bikes

[david451]

One last report in case it may be useful for someone else:

The problem is solved, at least its working fine for now. Seems that either the gasket or the screws torque was wrong.

Thx everyone for the help.