www.zxrworld.co.uk

I have a bit of a problem....

Was tightening the 1st headbolt up after replacing the head gasket and it snapped HALFWAY DOWN

I can see the bolt about halfway down the cylinder block and not sure how to remove it.

The engine is still in the frame so I'm guessing this is an engine out jobby.

Anyone know the best way to get it out?

Thankingyou

Your first mistake was too even try a job like that with the engine in the frame.

The good news is that the barrels will easilly come off once the head is removed and you'll have access to get a grip on the remains of the broken bolt.

It will however be a pain in the butt getting the barrel back on again...............doable but a pain

been thinking about this

It might be possible to just lift the barrels off enough without lifting right off the pistons to get a grip on the remains of the broken bolt to turn it untill it's free of the threads then drop the barrel back into place and use a magnet to reach into the hole and lift the bolt out.


If that works it will avoid the pain of getting the barrels back on to each piston and save a lot of time and hassle

Great, thanks for the feedback,

I haven't looked in a while but are you saying that the cylinder block doesn't have thread on it? Just thought it wouldn't be able to move it if it is screwed onto the bottom end...? And will it not wreck the gasket underneath?

Sorry for the questions it's just I want to get it right this time round as im running out of time and money.
Also doing the gasket in the frame wasn't hard at all - I just didn't take it easy enough when tourqing the bolts back up.
Silly mistake.

Thanks again

There is NO thread in the cylinder block just a hole the bolts thread into the crankcase. So the block will lift but as I say just lift it enough to get a grip on the broken bolt.

The base gasket is an aluminium one and it should survive being disturbed. If it does get damaged just remove it and use a little gasket sealer when you put it back together..............removing that gasket is a common mod you slightly raise the compression ratio by removing it......................provided the head is standard and not skimmed there are no valve/ piston issues

Thats is fantastic news!

Thanks for your help - the head has been skimmed so it's probably wise i keep it in. I will let you know the progress and upload pics etc

OK bad news. The bolt isn't visible when i lift the cylinders. It's buried in the crank case.

Anyone have any suggestions?
Engineers?
New bottom end?

thanks

How deep in is it ?

It might actually be loose ? ?

Given that new crankcases are very very expensive and you dont seem to be that experienced in such matters I'd say get an engineer or a really good mechanic to look at it.

You might be able to drill a hole in the middle of the broken bolt and use an easy out ( left hand thread tapered broken stud remover) but these are not fool proof and if one of them breaks off in the stud then you really are up 5hit creek.

Heat will help get it moving in fact heat followed by instant cold and reheat............is even better.


If it was me I'd try just tapping it round with a small chisel or screwdriver depends on how much of a purcahse you can get on it if that failed then I'd try the easy out.....but very very carefully so as not to break it.

ITS OUT!!!

I now know not to rely on someone elses word when they say its f***ed.
My mate said he lifted the cylinders but he actually hadn't and stressed that I need a new bottom end. I was not amused to find he hadn't even touched it. Sooooo.......

I lifted the cylinders to reveal about 2mm of broken bolt - not enough to get an extractor on it.
I took a trip down to a hardware shop and purchased a bag of hacksaw blades for £1.99,
When I got back to my unhappy ZXR, I sawed a groove into the bolt (took about 10 minutes and 3 blades)
I then put the cylinders back down and UNSCREWED the bolt.
The sun shined, the birds sang and I made a mess in my pants when I saw the bolt clinging to the screwdriver on extraction.

I definatley am not going to snap another one - that was awful.

Thanks for your help

Dont ya just love a happy ending

isn't it ironic - you mess the back of your pants when the bolts snaps, then the front of your pants when it comes out!

I did make a smelly brown mess when it snapped...

Do you guys think I should get a whole set of bolts or just replace the one?
I was thinking about torque settings and thought that the old ones may have stretched a fraction.
If I get it going and the new bolt stretches the gasket might go again - or just change torque settings?

Also I still have the gasket from when I first started putting it back together - think I could re-use it?