Removing an engine

552 Views 4 Replies 4 Participants Last post by EJR, Apr 2, 2017

10Arghh

Discussion Starter · Mar 27, 2017

This is for an old 98 ZX6R but I guess the design will be similar to other inline 4 engine Kawasaki bikes from the era, so I hope someone can help.

I've loosed off all bolts as pictured, except for the one with the collar (highlighted).

I've removed the nut but the bolt won't come free from the collar...The bolt and collar seem stuck together and turn with each other.

I've tried applying heat to both, hitting with a rubber mallet...It just won't budge.

My last resort is to call in Mr. A. Grinder, but I've just realised that Kawasaki have deleted the bolt from their parts catalogue (you can still buy the collar

).

What I plan to do then is to carefully cut down the length of the collar without damaging the bolt.

Unless.....Is there another way?

Thanks.

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michael4012

· #2 · Mar 27, 2017

If you removed the nut from the other end then the bolt should just pull through or maybe a tap from from the threaded side where you removed the nut might move it but if the weight of the engine is still on the bolt then it may all tumble out.

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10Arghh

Discussion Starter · #3 · Mar 27, 2017

michael4012 said:
If you removed the nut from the other end then the bolt should just pull through or maybe a tap from from the threaded side where you removed the nut might move it but if the weight of the engine is still on the bolt then it may all tumble out.

Cheers mate...Yeah bike is supported by a swingarm center lift (Abba stand)

And I have a hydraulic lift to support the motor, which is pressing against the bottom of the engine to relive the stress on the frame.

If I lower the hydraulic lift, the engine pivots on that one stubborn bolt...So it is free, besides...I just need to get that bolt out.

The bolt is like it is welded to the collar....Should I just cut it off (the collar that is)?

Cheers

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C3L1CA

· #4 · Mar 27, 2017

If it were me I'd try some PB Blaster (rust penetrating stuff) on that collar/bolt and keep it hitting it with that fluid like every 10 minutes for an hour.

Then I'd give the end you removed the nut from a tap with the rubber mallet and see if you can break it free.

Then maybe try spinning the bolt with an wrench or air impact while tapping on the other side with a rubber mallet.

If that still didn't break the collar and bolt free I'd try and hold onto the collar with a locking pliers and hit the bolt with an impact.

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EJR

· #5 · Apr 2, 2017

Heating is not necessarily a good idea in this situation and can actually make it worse depending if the collar is made from a different metal than steel. On such a small item, where you cannot freeze the whole thing first, you may be heating the inside enough, causing it to expand more than the outer collar (given this happens depending on the different types of metal- aluminum typically expands more than steel, so this would be an aluminum bolt with perhaps a steel collar). I would try wedging something in between the frame and collar. Do no grab the collar with vice grips and try to twist it off, as you will probably crush the collar right onto the bolt. If all else fails, cut the damn thing off. You can buy bolts with long shanks like that all day at hardware stores, I wouldn't worry too much.

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