Sump boss sheared - need help big time

[The Tot]

I was planning to do mallory park this weekend with my mate so i got the bike prepared by bleeding the brakes and cleaning the calipers, a routine job that i've never had much problem with in the past.

When it came to doing the oil change... that's when the problems started. Righty-tighty, lefty loosey! Anticlockwise selected... removed my fairings okay, but when it came to removing the bolt... GRR it's not moving! Applied a bit more force, oil pisses out after bolt comes loose... Along with bits of the sump! Upon looking at the bolt, i have found to my dismay that there is NO crush washer in the bolt and a huge amoung of thread stripping.

Pics attached here.


Now, what would be the best solution to the problem - the sump is going to be taken off (took the headers off no problems BUT a few of the bolts have sheared in the sump making removal a bit difficult).

My options are 1) Get a new sump SO IF ANYBODY HAS A SPARE ZX6R F sump, I'll be wanting it
2) Find a local engineering firm in loughborough to weld the sump boss together and weld it shut. Tap a new M10 hole for the sump bolt in the ally.

Any other suggestions - i've used liquid metal before and i DON'T want to use it again - the bike DID run for 12 months on it.

https://w3.bikepics.com/pics/2008/10/28/bikepics-1464443-full.jpg
https://w3.bikepics.com/pics/2008/10/28/bikepics-1464444-full.jpg

If i can get stuff sorted before saturday, trackday's on, but if not
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The Tot 2019 Z1000SX - 2007 R1
Never argue with autism

[SoND]

Get it welded and clean it really well before you take it to them.
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Go back to bed - You have no rights - "Streetfighters ~ Mainstream motorcycling's crackwhore sister."

[The Tot]

Err, i just paid 10 magic beans for this https://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=130241865339 .
I haven't paid for the trackday yet since my mate was organising it. BUT if i get the new sump for friday, fitted... then i'm laughing. I won't need a sump gasket would I? I presume that silicone gasket that my mates use on their cars will suffice?

I don't want to be known as the looney noob that pissed all over Gerard's writing off a load of spanking new bikes in the process! It's not THAT imperitive that i go on a trackday since many more will indeed come, but I'd rather get my last kicks before toning down my riding during winter

For the time being, the bike is laid on its side like so
https://w3.bikepics.com/pics/2008/10/28/bikepics-1464489-800.jpg

If i can get it welded for cheap, it'll be OK, but that's going to be another problem for another day when it comes to changing my oil!
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The Tot 2019 Z1000SX - 2007 R1
Never argue with autism

[SoND]

[ZRX61]

[The Tot]

I kinda figured that anyway since i don't want oil leaking on my rear end causing a highside. I'll be ordering a set of gaskets for the sump and exhaust tomorow and i'll use the silicone stuff as well to double up.
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The Tot 2019 Z1000SX - 2007 R1
Never argue with autism

[ZRX61]

[The Tot]

Cheers - man, bad luck ALWAYS come in octobers!

last year - lowside, crashed and did £2000 damage!
2 years before - routine oil change - knobend, namely me torqued up incorrectly and stripped the drain plug threads
THIS YEAR - err this!

Anyway, standard gaskets it is then - I've figured now that it pays NOT to bodge.

Boy, putting the downpipes back onto the bike is going to be a right laugh (took me 2 hours last time purely because it needed 2 people... the TI downpipes are soo tight!)
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The Tot 2019 Z1000SX - 2007 R1
Never argue with autism

[djr]

[Ariel Badger]

PTFE tape on the thread for the seal. It will stop it seizing again as well.
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Bikers make great organ donors, get 115 on your licence today.

[djr]

[The Tot]

managed to get the sump off. we're going to try the blowtorch approach on the stud that's got no exposed threads. The other one, we'll weld a head onto the bolt and turn it with a spanner.

It turns out for some reason that the gasket was cardboard! I would have thought it was some rubber or elastomer gasket of some sort!. But i'll have to scrape off ALL the gunk off the crankcase surface when it comes to putting the new gasket on. I'll order whatever's in stock at cradley.

PTFE tape on the thread is a good shout too.

Coppergrease on the exhaust bolts probably won't be necessary. They went in OK when i put them in last. My main concern is that the tolerances are so tight that you have to pull the headers a considerable amount... i.e. from bank 1 to bank 4 in order to align it with the studs.

Either way, it's not a major problem now that i think of it. Sump came off after a battering with a wooden pole.
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The Tot 2019 Z1000SX - 2007 R1
Never argue with autism

[Ariel Badger]

To get broken bolts out try this...
Drill out the centre (with care and precision) do not use a stud extractor but hammer the tang of a file up the hole and turn it with an adjustable spanner. Extractors tend to expand the thread and tighten it into the hole, the tang does not.
Remember, heat is your friend.
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Bikers make great organ donors, get 115 on your licence today.

[SoND]

[djr]

[The Tot]

My bad, i used some other sort of grease - LM grease on the gaskets the other time - i don't generally like reusing gaskets or washers. I've got a wodge of copper grease somewhere as well and i remembered how much of a pain it was to keep the washers inside the header flanges! So yeah, that'll be fine.

Ariel, I'm not risking the drill centres. I'm just too afraid because the diameter of the bolts are simply too small to drill accurately using a power drill. But yes, a blow torch is necessary to heat the ally just enough that it expands away from the bolt - miniscule but more than enough to unsieze it. Looking at the sump bolts, there appears to have been a LOT of galvanic corrosion between the steel and the ally - grease will do nicely on the new bolts though.

I'll offer these suggestions to my mate since i'm sure he'll probably have some inventive ideas.
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The Tot 2019 Z1000SX - 2007 R1
Never argue with autism

[Odie]

Try S.E.P in kegworth (just up the road from loughborough)
there number is.................01509 673295, ask for Ken.
they have done stuff for me like this before so it shouldnt be a problem.
odie
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