VF500 restore off to a bad start....

Front engine bolt seized solid. Had to grind head off bolt to get the engine out of the frame. Gonna need to get bolt out before I do anything else... thinking of cutting through the bolt, then deal with the two halves separately...
Also found one of no.3 exhaust studs missing. Not sure if I can reattach a stud to the broken engine case.

I ask myself, is it really worth it?

 

I would say it depends on the condition of the rest of the bike…


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Yeah.... compression good, cams look good but lots of perished rubber stuff, frame needs repainting, forks leaking...

Ho hum... starting to make an inventory as to costs, but will have to sort engine bolt out before I consider raiding the piggy bank

 

Sounds like lots of small things but they do take time and some money. I personally enjoy resurrecting zombie bikes ( not saying yours is ). Most of my fleet was given up for dead at some point.
Keep us posted please


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A start like that does take some wind out of the sails, for sure. But as things start happening and little victories are taken, it feels good.

Start soaking EVERYTHING. Often.

So the missing stud is broken off below the surface?

 

Hi Cap'n
Yeah, the casting appears to have been damaged - certainly one side seems chipped away.
There may be sufficient metal left to fix to, as the stud was still in position, but it must have been held there effectively by the other good one and the exhaust ring.
When I bought the bike, the silencers were off the bike and I found the collector box wasn't fastened to the motor apart from the headers - makes me wonder if it's had some sort of bang that's caused the damage?
Anyway, onwards and downwards...

 

OH. Dear. Now I see.

That game plan and success or failure is top priority then.

 

It is indeed.
Apart from the exhaust stud issue, my first task is to sort the seized engine mtg bolt.
I have no means of heating it up so if release oil doesn't work if will have to be a slow careful drill job. After that I'll know whether to move on to painting the frame etc or as a last resort it will be a part out job - hope it doesn't come to that!

 

The cases are not threaded, it is just a thru bolt. Like I said, start soaking and keep soaking. If you can't get movement as is, I would cut the exposed threaded section off nice and flat. And then cut the center section out between the lugs. Then I would use the biggest drift that would still go thru the hole, combined with a suitable big hammer and start a whackin.

You have no access to heat? Even just a little butane soldering torch would help, but a bigger torch on a propane bottle would be nice. Shit, even a heat gun on high will help.

 

Thanks Cap'n, I appreciate your suggestions.
I forgot about my plumbing kit - I have a small blowtorch somewhere - as you say, better than nowt.... will give it a go asap.
I know the cases aren't threaded but I'm worried about damaging the castings if I take a big hammer to the bolt.... hopefully I can get them hot enough to twist them out.
Failing that I will see if anyone I know has a more powerful propane torch I can borrow.
Watch this space!

 

I get it about possible damage. Heat will be your friend along with a good penetrating solvent/oil.

Good luck!

 

Kroil works great for me!


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PB Blaster is a good penetrant also.

 

It is very good. I have to relegate to outdoor work tho, as it STINKS. I'll come down to the shop the next day, and WHOA!

 

Kroil smells like oil … ha ha ha


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Thanks guys, gonna order some of the smelly stuff and give it a go, if nothing else it'll keep the missus out of the way!

 

Success!!!

After much cursing, soaking with Blaster, heating up with a blowtorch, I had to resort to drilling the remains of the bolt from the right hand side.
Using an angle grinder I cut out the centre part of the bolt so I could work on each side separately. The remaining left hand piece came out fairly easy after soaking it, then drifted it out. The right hand side was not for moving at all - this boss is 35mm long so it had a good hold on the bolt. I ended up drilling in from the right to a depth of about 30mm before I could drift out the remaining piece. As careful as I was, my drill ran off a tad, but at least the crankcase mounting block has survived, albeit with a slightly bigger hole than before.
I hope things get easier from here on!

 

[/QUOTE] pics showing my wrecking progress!

 

That is crazy! Nice work. This should be a fun space to watch!