Broken case saver bolt bosses.

Broken case saver bolt bosses.
Posted by Mercenary223 on 30 Mar, 2013 23:00
So When I picked up my lt250 I had not noticed that the upper case saver bolt had sheared off and the lower bolt was gone along with a chunk of the bolt boss. Also when I tool my stator cover off the lower bolt that the stator wire holder attaches to was **** and a little chunk fell off as I removed it. Any way I broke 2 drill bits but managed to get a hole drilled and my extractor to pull the upper bolt out. Anyway the inside of the stator looks good and tight for sitting 15 years I am just a little bummed about the case missing chunks. I have attached a couple pics to show my surprise.

#2 Reply
Posted by JayTater on 31 Mar, 2013 07:26
Quote from: Rainman56 on 31 Mar, 2013 07:10
Just so ya know the case saver bosses can be repaired.

Exactly. Just have to find a reputable welder that is good with aluminum. Be thankful that Suzuki didn't do like KTM and switch over to magnesium cases.

#3 Reply
Posted by SBLT500R on 31 Mar, 2013 11:05
Quote from: VoodooChassisWorks on 31 Mar, 2013 07:26
Exactly. Just have to find a reputable welder that is good with aluminum. Be thankful that Suzuki didn't do like KTM and switch over to magnesium cases.

magnesium can be welded. i've welded transfer cases before. just need magnesium tig rod.