Firstly… Happy New Year to all.
I was going to reinstall my rebuilt engine but found that the upper rear engine mount with the bushes is approximately 3.5mm wider than the bracket.
The bushes were pressed in and are fully home and the brackets look straight.
Think I need to remove the bushes and get them machined or find shorter ones.
The old bushes were burnt and chiseled out when the cases were split.
How to remove them on a built engine? There doesn’t appear to be a space to use a blind puller.
Thanks,
Mike

Cut off the 3.5 to fit? 

Not enough info to know exactly what's going on but I'm pretty darn sure you won't get those bushings out without carefully cutting them out somehow. 

Even if old bushings were bad, there is an internal spacer so bad bushings wouldn't cause the bracket to be bent in.  I have seen where the internal spacer was missing and the frame brackets are bent in slightly...  even though they look straight.  (The internal spacer sometimes gets badly rusted to the bolt and people leave them out on reassembly...  it really is needed with the rubber bushings)

You're talking about roughly 1/8" inch total or 1/16" per side.  A thick layer of powdercoat could cause that.  If frame was powdercoated I'd grind it off the inside of the brackets and/or bend the brackets slightly wider. 

Checked an engine I have out of the frame, mount measured 79mm total, 5.75mm sticking out on the drive sprocket side, 2.25mm sticking out on the kickstart side, might try running a nut down on a bolt in the mount to see if you can compress the bushing to make up the difference? 
photos.app.goo.gl/cnYYPKRXJwjscyaBA

Thanks very much for the helpful replies… especially the measurement. My bushings measure 79.03mm, so seems like my brackets need “adjusting” (75.70mm).
The collar was fitted and it’s not powder coat that is the problem.
Really useful to know that I do not need to worry about the bushes and focus on the brackets.
Thank you - this is a great site!
Mike

 

If you put a bolt through & it pulls up to spec then is the outer steel part right home in the case on both sides.
Center part if compresses 'being bonded rubber' will spring back untill the outer is right home.
Might be able to get a socket against the outer & give it a smack on both sides to bring them both in a little. Case will be stepped I guess so can only go to that step. Seems unlikely Yamaha would alter things like that between models but ya never know.

I would stick a length of threaded stock thru both brackets and use hex nuts to draw your brackets in or out.

Thanks very much for the responses and suggestions.Opened the bracket up as per Schu’s suggestion and engine now fitted.Now to complete the installation and do first start up after rebuild. Fingers crossed for that!Thanks again,Mike