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rusty bolt

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tfcoulson View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tfcoulson Quote  Post ReplyReply Direct Link To This Post Topic: rusty bolt
    Posted: 23 Apr 2020 at 16:48
Has anyone any good ideas to remove this engine case bolt?
Nearly all the clutch cover bolts snapped, and this engine case bolt after I'd abandoned trying to get the cover off without any damage.
This particular bolt is so rusted in its snapped twice already, and had a bolt extractor stuck in it. And that wasn't even the part that screws in, it was the flat parts of the bolt.
It's been sprayed plenty with seized bolt stuff.
I'm thinking I might have to just drill it out and not have a bolt there :/
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tfcoulson View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tfcoulson Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 16:49
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davidrsurfer View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote davidrsurfer Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 16:58
Fire, then if it snaps off drill it down the centre in increasing diameter drills until you get to the tapping drill size. By then it will have either wound itself out or you can pick it out.
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Pete 86 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Pete 86 Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 17:12
You need a plumbers blow tourch to get the casing hot. Or heat gun. Get a pait of moal grips on it first if you cant get a good size pair on it get a little pair and make sure they are tight as you can.

They have to be on the bolt at 90' not straight with the bolt.
Wiggle side to side little bits . 
If it will eventually crack .

The crack is when it cracks dont try unscrew it right out it might bight again.
You have to treat it like tapping a thread.  Loosen, tighten, loosen more, tighten. And repeat.   When you put moalies on it they will proably slip a fiew times but dont worry whats happening is you are wearing the threads away
This is good because your creating a solid shaft to grip if that makes sense.

You can also try putting 2 nuts on it if has ant threads lock them togeather and use a socket same process as moalies.

Take your time dont rush . It will give up eventually.
If you rush you will have to do it the hard way like dave said with drills.

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legend88 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote legend88 Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 17:18
Originally posted by davidrsurfer davidrsurfer wrote:

Fire, then if it snaps off drill it down the centre in increasing diameter drills until you get to the tapping drill size. By then it will have either wound itself out or you can pick it out.

And use a left handed drill bit as that often teases them out on it's own
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Post Options Post Options   Thanks (0) Thanks(0)   Quote kommando Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 17:25
Originally posted by legend88 legend88 wrote:

Originally posted by davidrsurfer davidrsurfer wrote:

Fire, then if it snaps off drill it down the centre in increasing diameter drills until you get to the tapping drill size. By then it will have either wound itself out or you can pick it out.

And use a left handed drill bit as that often teases them out on it's own

In my toolbox too, very useful and 50% of the time the offending bolt comes loose. One  RH dril and rest LH.


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tfcoulson View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tfcoulson Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 17:35
Unfortunately all of that has been tried  Cry

Left hand drill didn't bring it out (tried that with the bolt remover),
Mole grips eventually ended up snapping the last section.
I can't get a good central drill on it either because of the frame, and the drill bits are too short.
I haven't tried the 2 nuts idea though, might give that ago.

Will have to take the clutch basket out to get the mole grips at that angle, might be next option
Thanks

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tfcoulson View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tfcoulson Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 17:42
Clutch spring bolt has now snapped.
Pretty much had it with this bike
Think it's going in the bin
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Pete 86 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Pete 86 Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 17:48
HEAT HEAT HEAT!!!!!
its the magic ingredient 
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wigginsjp View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wigginsjp Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 19:02
Heat and a release spray , better still soaked overnight. May take a few cycles. Have you access to a welder? I'd weld a nut onto the existing thread. You will also find the heat generated on the bolt will probably be better than a blowtorch in a concentrated area. Just unplug the stator first then a socket with heat may shift it. This will come out. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wigginsjp Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 19:02
Oh and avoid molegrips where you can as they almost always slip unless it's loose and generally make life harder 
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tfcoulson View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tfcoulson Quote  Post ReplyReply Direct Link To This Post Posted: 23 Apr 2020 at 19:52
Heat worked...for 4 out of the 6 clutch bolts Handshake
Then when I was loosely putting them back in for the night so I dont loose them, Id barely nipped it closed and the head fell off another Ouch
Its loose though so should come off with a lefty drill bit.
No access to a welder unfortunately and I couldn't get a nut on the bolt as it was pretty manky.

Need a clutch holding tool before I can go any further.
Wigginsjp, if you'd like to come over to Dublin with your welder be my guest haha. This thing has been a nightmare since day one. I told myself Id never buy another 20 year old bike again, must drop that down to 10.
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