Seized Front Cylinder Nuts

[tywill]

Hi I thought I would share my recent experience of removing the front 2 cylinder nuts (long aluminmium) from my TY250D. These nuts were seized solid I tried the following methods to remove them because I thought they were seized on the crank case studs:

1) Impact wrench (24v electric) - Did not budge.

2) Long extension bar and 13mm socket with a blow torch heating up the nuts - Resulted in rounding the hex shape of the nuts.

3) Drill a small hole in the top and spray liquid wrench onto the stud inside the nut, then use a irwin bolt extractor with a long extension bar - resulted in the hex section of the nut shearing off completely.

At this point I was considering buying a 2nd hand cylinder, and using a disc cutter to cut the cylinder free. But then took a closer look and saw the nuts had actually corroded them selves on to the cylinder. So tried a new approach:

4) Using a 19mm hole cutter with the center drill removed, I managed to remove the out 2mm of the nuts freeing them from the cylinder, then using a 14mm long socket hammered onto remainder of the nut, I then used a impact wrench. - Success both nuts came out really nicely, No damage to the cylinder or the studs

I hope no else has to go through the process that had me worried for 3 days.

Edited October 5, 2011 by TYWill

[feetupfun]

Its actually a very common problem Will. My technique is a bit different. I drill the steel stud away using a drill guide that fits neatly into the holes through the fins.