Froze up TSS

S

stinger440

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Dec 22, 2009
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Age
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Location
GR MI
Starting to tear apart the front end of my 84 phazer and pretty much every bolt is froze up. Anyone have any good tips for getting out bolts that are froze to the bushings? Or do I just need to start cutting and replace the bolts? I already have new sleeves and bushings for the front end so I don't care if I destroy them. Thanks in advance.
 

It's been a few years since I have done that, but I recall it being a tough job with lots of cutting, soaking in oil, pounding and even an Arbor Press to remove some. The steering knuckles should have had grease zerts on them...
 
could always try a welder. it is hard on the welder but you clamp the ground on one end and the whip on the other. heats the bolt red hot and when it cools the bolt breaks loose from the rusty parts very easy. hammer and press are safer though.
 
Get a torch and heat them up and they turn right out. If you press or beat them to death, most of the time the metal just bends and ruins the links. Jeff Wurl
 
There are plastic washers that you will melt by heating the mechanism so you'll have to replace them. I have gotten them apart by heating then quenching the parts with a penetrating oil. I always have to repeat this process for several cycles but the heat and oil will help. If you can remove the entire TSS from the sled then using the heat, oil and a press would surely be the best way.
 
i had an eciter that had the same issue. i ended up cutting them out and replacing everthing. if your local dealer uses Marshall Distributing, they have a shim kit for the TSS set up which will take the slop out of those also.
 
You will need to replace all the bushing anyways to get the slop out of the steering. All the aftermarket supliers sell the bushing and shim kit. Jeff Wurl
 
Thanks guys. I already have the shims, plastic sleeves and bushings, just need to get these apart. I will try the mapp torch and see if that works, if not I think I will be cutting them apart. I wish the original owner would have used some freaking antisieze or at least some grease.
 
On every used T.S.S. sled I've bought the Knuckles and steel bushing are almost frozen or completely locked up and pivoting on the bolts ! I've bought sleds that the locked up joints won't even allow the springs to return let, alone the struts to work when hitting a bump. The T.S.S sleds have always gotten a bad rap for slop developing when the ungreased steel bushing's freeze up they grind away on the nylon washers ! I have sleds that are 15+ years old that have never had a bushing kit and are almost as tight as new. Just take the knuckles and the ski mounts apart every other year and grease !
 
Update on the project. The front end is has been disassembled. I had to cut the bolt at the middle joint on each side. On one side I had cut the top arm off around the bolt and pound out the bolt/sleeve. I had to cut out one ski mounting bolt and pound out the bolt/sleeve. I have all new bushings/sleeves and enough bolts to replace the cut ones. I have to get the ski mount sleeves and then I can put the front end back together. GREASED WELL!!! Thanks for all the tips guys. Next I get to tackle the rear suspension.
 
stinger440 said:
Update on the project. The front end is has been disassembled. I had to cut the bolt at the middle joint on each side. On one side I had cut the top arm off around the bolt and pound out the bolt/sleeve. I had to cut out one ski mounting bolt and pound out the bolt/sleeve. I have all new bushings/sleeves and enough bolts to replace the cut ones. I have to get the ski mount sleeves and then I can put the front end back together. GREASED WELL!!! Thanks for all the tips guys. Next I get to tackle the rear suspension.
Click to expand...

Where did you find the bushings/sleeves ? All I have seen in Aftermarket are the washer kits. Thanks !
 
Its funny you ask about the bushings/sleeves. About 4 years ago a guy I work with got out of snowmobiling. Him and his father in law had SRV's and Exciters and they kept their sleds in tip top shape. Well he gave me all their extra parts and stuff. All sorts of bits and pieces still in yamaha packages. Because I have all these yamaha parts I figured I should buy one. I have not had to purchase any wear items yet.
 
someone used to make bolts for TSS that had grease fittings and distribution chanels built into them.

IF TSS would have had greasable joints, the term 'YamaSlop' would not have come to be. You can add fittings when you rebuild it, but you have to consider the linkage moment when you add the one for the linkage pivot on the ski saddle.
 
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