I have a Suzuki T500 and recently removed the rubber engine mount bushings. One of the holes where the bushing is installed looks to have been worn to the point it will no longer allow for a press in fit of the new bushing. I have no idea how this could have happened. When i took the old one out, it slid right out. Normally, these are real hard to remove. I measured the hole and it is approx 1MM larger than the other holes. I checked for cracks around the mounting hole in the case and there are none. Any ideas what I can do to fix it outside of trying to get another engine case?
Engine case worn-need ideas
- Thread starter worldcafe
- Start date
Maybe epoxy the new bushing in with JB weld etc? Probably you will never replace the bushing again. Normally I would recommend welding and machining as already suggested, but this will be fairly difficult to do, and if you do replace it again in the future, you will have an unfriendly task removing the epoxied mount, but not be any worse off otherwise. If you do take this path, temporarily install the mounting bolt through both bushings to align them until the epoxy cures.
another note on the epoxy, do the job with the parts and epoxy warmed up at least 90f or so and use the stronger slow set and sometimes the epoxy wants to flow and will fall out uf a gap so some type of dam or packing in behind will stop this it could just be a washer shaped piece of cardboard
Thanks for the ideas. Welding and machining is probably the best option, but the most expensive. Not sure how I feel about the epoxy option, although that would be the easiest and low cost. I might have the future owner of the bike cursing me out on this forum 15 years from now trying to figure out why the hell he can't get the bushing out. I don't have any experience with machine shops. Anybody have an idea how much a shop might charge for that type of work?
Sent from my iPad using Tapatalk
Sent from my iPad using Tapatalk
if you are not sure about the epoxy then don't fly on a jet airplane
epoxy correctly done with nicely preperated surfaces is the perfect solution
welding is a bad idea the jap casting is dirty as fook and it is not at all that easy to weld down inside a hole,infact it is dam difcult
epoxy correctly done with nicely preperated surfaces is the perfect solution
welding is a bad idea the jap casting is dirty as fook and it is not at all that easy to weld down inside a hole,infact it is dam difcult
Right. A die grinder will carve it out pretty easily. FWIW, I have had similar bushings that had to be pressed out, and some that left the outer steel case in the casting after pushing the rubber and center spacer out. You have to split the outer casing with a die grinder to get it free in such a situation, no more of a PITA than if it were epoxied. I've seen the castings broken too from inept attempts to remove similar bushings as sometimes they are seriously hard to remove and require great care and proper back support to keep from doing damage. My point is, you may not be necessarily be saving that future owner anything by trying to restore the press fit assembly. You likely will also have to do some pretty delicate grinding/filing/shaping of the non-machined welded surface to make it reasonably invisible - welding in places like that usually gets a bit messy. It is also easy to lose the original center point after welding unless you plan ahead pretty carefully.
Don't think of epoxy as a lazy stop-gap solution (though it can be, of course!). It is just another tool in the engineers arsenal of weapons. Right tool for the right job is the rule, and structurally, this is an ideal application if you use the right material. As already noted, you trust your very life to epoxy every time you fly on a commercial jet.
Don't think of epoxy as a lazy stop-gap solution (though it can be, of course!). It is just another tool in the engineers arsenal of weapons. Right tool for the right job is the rule, and structurally, this is an ideal application if you use the right material. As already noted, you trust your very life to epoxy every time you fly on a commercial jet.
