1989 DT65 Thermostat Removal

[tinkerr]

Attempting to replace poppet 2 of the 3 bolts broke off. The housing appears to be seized on the longest bolt. Any ideas how to unseize it and then remove the broken bolts? I'm afraid to put heat on it(torch)might create a bigger problem. I attempted to use a heat gun but, not hot enough I think. Thanks

 

[robert graham]

Re: 1989 DT65 Thermostat Removal

There is a product called Loctite Freeze and Release available at your local auto parts store....uses extreme cold to shrink metal parts/fasteners to help with removal....

 

[tinkerr]

Re: 1989 DT65 Thermostat Removal

Well, I took a chisel to the long bolt stem of the housing and beat that rascal off. That worked ok and left me with one long and one short bolt broken. Got the long one out pretty easy with heat, no luck on the short one, tried heat and the Loctite stuff, broke off flush. Drilled and tapped it, seems ok. Suzuki used standard bolts should I replace with stainless? Does anti-seize work on these bolts?

 

[robert graham]

Re: 1989 DT65 Thermostat Removal

Stainless bolts will work fine...I use marine grease on the threads to keep water out...easier to remove next time!

 

[99yam40]

Re: 1989 DT65 Thermostat Removal

Well, I took a chisel to the long bolt stem of the housing and beat that rascal off. That worked ok and left me with one long and one short bolt broken. Got the long one out pretty easy with heat, no luck on the short one, tried heat and the Loctite stuff, broke off flush. Drilled and tapped it, seems ok. Suzuki used standard bolts should I replace with stainless? Does anti-seize work on these bolts?

Stay away from anything with copper in it when using on aluminum.
SS can have a problem with al also