Starting a TS185 project, have a few questions..

[XR Pilot]

Small update, I tried giving the bolt a firm whack with a steel drift but it didn't budge and I didn't want to crack the cases, so instead I tried moving the bolt back and forth with a breaker bar. It felt like it started to move, and it was moving further each time. Unfortunately I had the bike layed on its side at the time so I couldn't see the other end of the bolt, which wasn't moving. End result is the bolt has sheared its head. The engine is still in the frame but if I drill about 2-3mm off the end of the bolt I will be able to remove the engine from the frame, at which point I am going to contact the local machinist to see if he can drill the bolt out for me.

[Marc.com]

little bit of heat goes a long way, if you have one of those propane heating torches from the Cheapas autos, then get it out of the frame, heat the case a little and try tapping it GENTLY again. You get this where you combine steel and alloy with cadnium plating, then add a few years of water.

My blacksmiths tip on heating is don't get alloy things hotter than 120 degrees, spit on parts as you are heating them and you sooi find where 100 degrees is. Also heating and WD40 works wonders.

[jimson]

G'day XR could you put a picture up of the said problem I can't work it out as if the bolt is for the engine mount it should go through a plate into the engine and through the plate with a nut on the end.If you've broken the bolt it should be free to exit the whole. jimson

[oldfart]

Brake fluid is what you use if the bolt is rusted on to alloy cases.
If a small section of the bolt is on the other side weld a nut onto it ........then soak the F.....ker in fluid giving it a squirt and bang each time. Time is costing you nothing ....but impatient will lead to $$$

[XR Pilot]

Thanks for the advice guys, I appreciate it. I will get a picture up within the next few days, but basically the bolt has fused to the cases due to them being dissimilar metals. I can't remember the name for it.

jimson - I'm not sure if you've seen a newer TS185 motor or not, but its not like the old motor that uses 2 seperate removable plates, one is removable (which I have removed) but the other one is welded to the frame. This side is the one that the bolt head sheared off, and because there is *just* enough metal on the bolt still inside the metal plate, I can't lift the engine up to clear the lower mounting plates to lift the engine free from the frame. As they say, a picture is worth a thousand words

oldfart - Brake fluid sounds like its worth a try. Another option is getting a friend to press the bolt out, but I am paranoid about cracking the cases. As you say time is nothing, but all it takes is one slip up to destroy a pair of undamaged cases....  :'(

[pmc57]

Use your propane torch to heat the engine cases around were the bolt is seized. With the higher expansion rate of the ally, it should eventually break the bond with the bolt. This is when you apply the lubricant and work the nut still attached back and forth until the lub can get in (says Mrs Marsh) and it starts to loosen fully. Then you can try driving it out with a pin punch.
Then if all else failes, go the press, but make sure you support it close to where the pressure is, ideally a hollow tube just big enough for the nut/bolt to fit through.

[DR]

XR if the bolt is only a flyshit from coming away from the mount then 'my' next move would be to bend the frame tab out slightly with a shifter(s) to clear the bolt so to at least remove the motor for more carressing. The mounting plate is only crappy mild steel and can easilly be repaired and no-one will ever know sounds rough but it's effective and will make life a lot less stressful

[frostype400]

how big is the bolt you can get a tool called easy outs that screw into bolts after you drill a hole in them mechanics use them to get busted bolts out search easy outs on ebay you can pick up cheap sets the are an invaluable tool they are threaded so when you tighten them into the bolt the bolt spins the opposite way highly recommend trying them if there is enough bolt to work with thanks Michael.

[cyclegod]

A few spares for you in this lot...

http://cgi.ebay.com.au/SUZUKI-MOTORBIKE-X-3-BIKES-FOR-PARTS-Motorcycle_W0QQitemZ130298607737QQihZ003QQcategoryZ32074QQssPageNameZWDVWQQrdZ1QQcmdZViewItem