Telelever removal nightmare.

[DrAlf]

Following my recent crash I started to pull the bike apart last night. Heavy front damage and a twisted subframe. Last night’s focus was the front end. Wheel removed. Forks removed – which were no longer attached to the telelever post crash. Front shock removed. Stumped by the telelever. After a lot of head scratching I figured it out. My bike was rebuilt in 2012 – new short engine block installed and built up by an independent specialist. The telelever bolt – the great big one that goes through the engine – has been installed the wrong way round before the heads were bolted on. Consequently I can’t get the bolt out or remove the telelever.

Two options then –

Remove the head but the exhaust studs will almost certainly not survive
Cut through the telelever bolt – I have a spare.

Anyone encountered this before? Anyone cut through a telelever bolt before?

Suggestions – thanks

 

[Aidan1150]

Even though I have never had to cut a telelever bolt I would be inclined to go this route rather than having to start removing the exhaust header and the head itself, especially since you mention that you have a spare bolt to hand.

I think a good quality cutting disc in a four inch grinder should do the job nicely.

Usual caveat applies. You're on your own. At least until it's all done safe and sound.

Edit. Pictures of the job as you go along please.

 

[Tractors are go]

Cut the bolt, bosch do a good hand held grinder as used by thieving scum everywhere, probably quicker/easier.

Sent from my GT-N7105 using Tapatalk

 

[mikeyboy]

If your going to spend the time and cash to rebuild the bike,why not take the opportunity to sort it properly,
The exhaust studs are only going to get worse till they cause hassle,if the bike is going to be a keeper give it a good sorting!

 

[mikeyboy]

Take the heads off ,take to local engineering shop £60 £100 later ,refit

 

[GS Addict]

Minigrinder with a zip disc. BTDT on a wreck myself.
Lots of used replacement bolts out there

 

[DrAlf]

Telelever removed yesterday - junior hacksaw and 15mins graft. Starting to make some progress now. I'll deal with the heads once it's back on its wheels and mobile. Ta.