Two broken starter bolts on a 81 CSR 750 twin

Grind them flat, use the right drill bit for the tap and chase the threads.
ASteve

I get to play with these two bikes. Both do not have a title but I got them so cheap I could not pass it up! It is really not worth getting the 77 engine up and working as long as I have the spare 81 engine that I can use. As for the bolts in the 81, I think just pulling the engine partially out of the frame so I can get a good angle on those bolts should do the job.

I think the end result would be getting a ATV/UTV sticker and make this bike into a fun trail bike. I love the low end of these bikes and I think with the right setup it could be a fun off road ride.

Thanks again for all the input, I do think the 77 engine is dead, even the oil smells burnt or at least off. I am wondering if there is a bearing that might have froze on the crank? When I have time I might brake it all the way down and see what happened to it.

That did the trick, even though I thought it still went harder then it should have. I got the jugs off and it looks like everything is okay. I took some pics of the jugs and the pistons and will get them posted later today. I am still trading engines over to the 78 frame. It was going to be the old 77 kz750b but now it will be the 81 CSR. Still need to drill and tap the broken bolts.

Got the motor out today and on to a good working surface. Once I got the bolts ground off and a good center punch, the slow drilling with some oil went well. Took it slow and it went well. Tapped and ready to into the 78 frame in a few days.

Once in the frame I will work on the started clutch and make sure that it is working well and put some blue lock on the three bolts to make sure they do not break loose inside the cover. Above in this post is a pic of the wear marks from the other starter bolts coming loose and wearing the face of the bolts off or down.

Well got the 81 motor in the 78 frame, took off the forks, triple and replaced with the CSR forks and wheel. I wanted to keep the front brake on the rear part of the fork. Just something weird about it being on the front with the older bikes.

Here are a few pics of the seized engine, not too sure what will come of it, but for now it is just for spare parts. Also thinking of going with a good off road tire on the back, but I think it will have to be wider then this one.






Broken starter clutch bolts




I have been riding for a long time and never broken parts off a chain before, until now. KLR650

did the tapping with a piece of wood loosen the jugs or the penetrating oil or both do the trick?

I think a little bit of both. I think it was just so stuck that it needed a little help with the tapping of the wood. I don't think the jugs are too bad and the rings seem to be okay. The wood really helps, just make sure you take it easy and keep it even.