GP Engine Bolt Removal

[wink]

Hi just in the process of removing the original Engine Bolt from my 1969 Gp and it will not budge. I'm worried that if I persist in hitting it with a hammer (Dohhh) that it may snap the Engine casing.

It would appear that engine mount is moving with the bolt as I hit it, so I can only assume that the metal shroud inside the Mount has rusted tight to the bolt. I have put on loads of grease a bit of WD 40, but only limited movement. No advice in Sticky's book, so i'm pretty stuck (like the bolt).

Any advise please on the best way to tackle this and whether it's possible to damage the Engine Casing, would be well received.

Many thanks in advance, Chris

[ratty]

hi mate, soak it in parafin and or duck oil tighten both nuts on one side of the bolts(lock one against the other) and turn the whole center bolt,you might want to warm it up a bit hairdryer works ok!! dont tel the missus.if you lock the other side as well you can rock the bolt.i have shifted a few like this.

[Knowledge]

If you have to hit the engine bolt, hit it from the flywheel side towards the stronger chaincase side lug.

[Scooterso]

If you steadily add more washers to one side, you can slowly pull the bolt out. We use an air gun which makes it a bit easier, but you can use a socket as well. Start with 10 washers under the nut, tighten the nut till it runs out of thread, back the nut off, then go to 20 washers (and keep adding more) and it will slowly pull the bolt out without damaging anything. You can also generally then clean up and reuse the bolt. The washers are 16mm so you can go buy some flat ones from a hardware store if you don't have a box full of old ones like we do.

[wink]

Hi thanks for the response, the problem I have is that someone has had a go at this before and the thread on both sides of the engine are buggered.

I think the problem is with the metal shroud inside the engine mount (kick start side), if you hit it from the flywheel side, the mount starts to push through with the bolt as though it's stuck (flywheel side seems to be moving).
As the bolt and mounts are buggered and will need replacing, is there an easier way of taking off the mount and thus easing the bolt out from the flywheel side.

Cheers, Chris

[joespeed]

grind the threads on both side protect the rest of the scooter from 'grinder splash' with wet towels and cardboard weld a large nut on one side (the easy side to work from chaincase i would think)squirt plenty of easing oil on then turn the big nut both ways then ease a screw driver under the nut then a thicker screw driver then a cold chisel the a forked tool used for breaking ball joints on your car,keep doing this till it is all the way out if the fails then a padsaw between engine mount and frame do not keep bashing engine mounts rewelded on look nasty!
regards
joe

[Soulpunk]

be very careful (or get help from experts), as i know at least 2 careful persons ruining their top conserved SX200 by breaking off one lug off the casing having the same problem..

[Scooterso]

Have you used a good penetrating lube? we use PB Blaster (not sure they sell it over there).

if the ends of the bolts are damaged you can still cut down a bit to reveal good threads to use for the washer/nut method. you might need a thread file to clean it up a bit after cutting.

[vince]

Lots of advice there which you should be able to couple together to get the bolt out,try cutting the damged area away from the end of the bolt first then use the bolt extracting washer system. if this wont work and you think the case side is moving in the sleeve you could then drill away the rubber from both sides freeing the sleeve from the mount then tap the bolt out towards the flywheel side ( if the case side is loose as you stated ) this should then go through with relative ease, if you do use this method make sure that the end of the thread is not burred over so it will not get caught on the inner sleeve or the cones on the way out.

[wink]

Hi, many thanks for all the advice. After hours of work I manage to remove the engine bolt without cracking the block
As suspected the metal shroud on the engine mount was rusted solid to the bolt. The only way to get it out was to cut around the rubber mount until it was free and then tap it through, obviously the Engine mount is now knackered but it was anyway (Please, noone tell me that the Engine mount can't be replaced with the shroud taken out).
At least now I can carry on with the resto.
Thanks again, All the Best, Chris