As Martyn suggests, it is better to use a snug fitting socket/Allen key after drowning the bolt in WD-40 and leaving to penetrate.
I would advise to buy new bolts, I like to use stainless steel Allen key type to replace the annoying 10mm bolts. The usual size is M6 (starter case, RH side guard, airbox, fuel tank etc.) and M5 (clutch perch, handlebar switches etc), you will need a few different lengths.
Don't worry too much about the sprag clutch making noise as it does this even when new. It is when it gets louder that you should start to worry. Of course, if the bike is new to you, checking it as a precautionary measure can't hurt though.
I look forward to answering any questions that may arise while you get the bike up to scratch.
Jarrah
-- Edited by TT-R250M on Tuesday 19th of November 2013 09:20:29 AM
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2000 TT-R250M-
Spoiler
Ported & polished, 73mm bore, Wizeco piston, US header pipe, FMF Q4, #150 main jet, #52.5 pilot jet, throttle stop screw adjusted, larger snorkel, GYT-R air filter, NGK Iridium spark plug, 14/51 gearing, NOS +
I've recently bought a 2003 TTR after scouring the Internet for a few months in search of an offroad bike. I think part of the reason for choosing the TTR was the fact that there is such a high level of support for the motorbike available, mostly coming from you helpful lot here.
The bike seems to be in reasonable condition but there are lots of little things that need to be sorted out. Look out for the first of my many questions on the Repairs and Maintenance section.
I was just going to check the sprockets and adjust the chain...
But the front sprocket guard bolts were seized. Now removed but damaged heads.
Then I heard a slight clunk when I turned the engine off- I'd better check the sprag clutch.
In order to check the sprag clutch and starter motor I need to drain the oil. Oh, the filler cap is seized and its head is beginning to get rounded. I haven't even checked the oil sump bolt yet.
And the allen bolts on the starter motor crankcase cover looks feel they are seized and beginning to get rounded.
Jarrah, Do you use local engineering suppliers for your bolts or do you get them off ebay?
I use a local supplier, a lot cheaper and easier.
You should be able to find these at just about any hardware store or fastening store. If you look around you can find marine grade stainless steel also, this grade lasts longer than the usual stainless ones.
Jarrah
__________________
2000 TT-R250M-
Spoiler
Ported & polished, 73mm bore, Wizeco piston, US header pipe, FMF Q4, #150 main jet, #52.5 pilot jet, throttle stop screw adjusted, larger snorkel, GYT-R air filter, NGK Iridium spark plug, 14/51 gearing, NOS +
I have been using Plusgas to try to loosen the bolts but it doesn't seem to do much.
The seized bolts are very annoying but can be overcome. What becomes a problem is the previous owner not following your advice and not taking his time with them. Every bolt I need to undo seems to have been attacked and slightly damaged.
I definitely intend to buy a load of new, good quality stainless steel replacements.
