Great isnt it, a simple job to remove 4 bolts and replace what i think is a sticky thermostat on my ZX12 engined Indy. Yet the bolts have been made from cheese and i have snapped 2 of the lower ones leaving me needing some help. I cant even drill the remaining studs out as the gearbox is in the way meaning i have 2 options.

1, refit the housing with just the upper 2 bolts and hope it holds or
2, remove the head and drill them out.

Ive tried for the last few hours drilling, dremeling and drifting the studs but its going to end in tear if i do anymore with a possible hole in the water jacket.

So can anyone help me out? is there any tricks or is it a head off job?

Not really a happy moment for me which i have come indoors to have a drink and play some PC games before i set light to the thing.

[Edited on 10/6/11 by Moorron]

Best long term solution is to get yourself a proper engine. Something like a Crossflow or Pinto springs to mind. U know the Japanese put rice in their bread and even beer so there's no reason to assume they don't use it in motorcycle production as well.
Any way of spot welding a small ring spanner to the stud? Just using two bolts is highly unlikely to prove successful. Remove the head and try a stud extractor.

Is there any stud still proud of the housing ?

If so, weld a nut over the top of the stud, the heat will help release the stud, and unscrew as normal.

If you've got a stick welder you can weld a 3-4mm electrode to the bolt even if it's below the surface - something you can't do with MIG. You can then either weld a nut to the end of the electrode or bend it into a T-piece and unscrew the bolt. It shouldn't need too much torque because it's no longer under tension as the head's come off, and the welding heat may well free it up a little more.

both bolts are below the alu head, but i might try the welding tech as i need to really take the head off to sort it. grrr.

is there a chance i will split the head if i add too much heat with the welder?

quote:

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Originally posted by skodaman
Best long term solution is to get yourself a proper engine. Something like a Crossflow or Pinto springs to mind. U know the Japanese put rice in their bread and even beer so there's no reason to assume they don't use it in motorcycle production as well.


Well done skodaman you know how to kick a bloke when he's down. You wait until it's fixed and he cruises past you at speed when you travel along in your tractor powered car.

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