A forum for owners of Yamaha TTR250 trail and enduro bikes!

I have a number of fork yokes that have come off TTRs that I have broken for spares amongst which are some where the mudguard bolt has seized into the bottom yoke and sheared off when trying to undo it. 

With such a small (M6 I think) bolt in an aluminium surround, it is a nightmare to drill and "Easyout" 

I offer this solution to anyone with access to a MIG welder.

My brother and I spent an hour or so yesterday and had success with quite about 4 out of 8.

This was one of the easier ones as there was quite a bit of thread showing. The ones where the bolt shears level with the yoke are a nightmare!

The process is to heat the area up with a MAP torch if you have one and then spray with WD40 or penetrating oil. The process of rapid cooling sucks the fluid down between the bolt and yoke - if you are lucky! Then put a steel washer over the bolt and MIG them together. Then spray again whilst still hot.

Next weld a nut to the washer - and spray again!

Get the area as hot as you can with the torch and carefully try and undo the bolt. Hopefully you will get some movement. It is important not to get excited and try to wind it out straight away. These bolts are really really corroded in there! Just move it back and forth with the occasional spray undoing it a bit more each time. Repeat until it is out!

The ones on the "outriggers" are easier to remove as you can get their surrounding metal hotter. This one was easy.

A close up of one of the extracted bolts. It is amazing how hard in there it was bearing in mind how short the thread is!

We were successful with the four on the left, not so much with the others!

Good luck if you try this method!

Please let us know how you get on 

Brian