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Discussion Starter #1
I took off the highway bars (crash bars) and now I can only get one bolt per side in the top holes. I can't figure out why the bolts won't go in. I think the bolts hold the upper motor mount for the front cylinder. Could the mount have shifted just enough to bind the bolts? I can see the threads in all the holes, but the bolts will not screw in.
 

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hi there !!
first of all , hold your bike straigh line ,,,
loosen the others two bolts a little bit , and place a jack under the engine , raise the jack
slowly and at the same time use a thin screwdriver in one hole (left or right side) for to use like a guide , while screw the other bolt in place and then the second bolt , tightening the four bolts later. note: a little grease can help.
drive safety.
 

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hi there !!
first of all , hold your bike straigh line ,,,
loosen the others two bolts a little bit , and place a jack under the engine , raise the jack
slowly and at the same time use a thin screwdriver in one hole (left or right side) for to use like a guide , while screw the other bolt in place and then the second bolt , tightening the four bolts later. note: a little grease can help.
drive safety.
Sounds like good advise to me.
 

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Discussion Starter #4
Thank you. I will try this when I have a second pair of hands. Guessing it's just off a hair and that's my issue. I hope this works.
 

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Discussion Starter #5
So...yesterday evening, my brother and I took to the garage to try and jack up the motor. We backed the other two bolts out a bit and the motor still didn't move. We thought about loosening the rear mounts, but didn't know what that may do to any other alignment issues. We did notice however that the front bolt hole under the key hole has about 4 threads that have been cross threaded...gotta love a used bike, and the other side's rear hole is totally accessable, but you can't get the bolt past about 5 or 6 turns until it binds up. Thinking of running a tap (M10x1.25) gently through the holes and see if it will free up the threads and allow the bolt to go in. I think the person that put the highway bars on muscled the bolts in rather than taking the time to get it aligned.
 

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Gotta Love those "Ham Hands"
 

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hi, really you only notice than the engine moves when bolt it is screwed completely, the movement it´s minimal, the greater effort should be using the screwdriver like handle and that´s minimal also.
(as it is a used bike to check size bolts looking for the original, you can read about size at STAR MOTORCYCLE OEM PARTS at FRAME pages) also check bolt threads.
plan "B"
placing jack only maintaining engine and for example the left side bolt actually on place to remove completely , placing there the screwdriver or guide and try to screw the other bolt and then the second, sometimes work on this way.
I done this job before maybe four times on my bike and it has worked.
good luck.
 

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Discussion Starter #8
Well...took it to a buddy that has a shop. We tried and tried to get it to line up just right. Finally we decided that we would clean the threads on the bolt and the frame hole with the tap and die set and they went in fine. I still say the previous owner must have forced the bolts in the frame and cross threaded or somehow junked up the threads. oh well...they are in. bike is running. life is good.
 
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