Sheared exhaust bolt f**k

[Fizzyhair]

Well thought I'd replace my exhaust gaskets and loosened off the bolts but SNAP!!! it's sheared of with less than a mm sticking out the block. :-( any advice. I really don't have the stuff to be drilling it out.

[hampshirehog]

Weld a nut on it (with that small amount sticking out weld it on the inside) and hit it with penetrating oil. Combined with the heat from welding you stand a good chance of it coming off.

[Fizzyhair]

I can't weld lol

[Fizzyhair]

It's gonna be a nightmare to get out isn't it lol

[Nessism]

Broken exhaust bolts and broken carb float posts are both avoidable occurrences, yet we get thread after thread for these problems. It's frustrating that people don't research before running in to problems.

[hampshirehog]

It's gonna be a nightmare to get out isn't it lol

If you haven't got the kit it ain't coming out. I don't know what to suggest; you could get it down to your local bike shop for them to have a look at - if they will tackle it (loads won't). Failing that have you got a local engineering shop? They might have a look at it for you. If you can avoid pulling the head (and the cost of gaskets / time etc) you'll be on a winner. Whatever you do DO NOT use an eeze out or whatever it says on the packet - no matter what your next door neighbour / bloke down the pub says. It will snap and then you'll be in even bigger trouble.

[Fizzyhair]

Well I put it in with very carefully with a bit of antisieze and applied hardly any force removing it. My lesson was not putting new bolts in when I changed the exhaust.

[Digitus]

Maybe best to use studs and secure the exhaust with nuts. Thats the way im going to put them together again

[bccap]

Broken exhaust bolts and broken carb float posts are both avoidable occurrences, yet we get thread after thread for these problems. It's frustrating that people don't research before running in to problems.

I recently ordered a new right hand exhaust header. In preparation for its arrival I spray wd40 before every ride. Do you have other suggestions ?

[Agemax]

as above, i think you need professional help

[Fizzyhair]

Yea I booked it in to be tapped and turned out. Shame really it's the best the bikes run yet. Done all my clearances and finally got my mix right and then something like this happens. Never mind lesson learned.

[Griffin]

I've drilled out and retapped three broken exhaust studs over the years. I've done them all with the engine in place.

It's very dicey to perform, but it can be done. Each one took the better part of an afternoon to do.

[Nessism]

I recently ordered a new right hand exhaust header. In preparation for its arrival I spray wd40 before every ride. Do you have other suggestions ?

For one thing, get some penetrating lube like PB Blaster. WD-40 has some good qualities but not as a penetrating lube.

When you go to turn the bolts out use a 1/4" drive ratchet handle and keep the force low. If necessary, take a propane torch and heat up the bolts red hot, then let cool, and apply more PB Blaster. The key is to not exceed the bolts max torque, and use lots of lube. Turn both in and out, a little at a time. Work it back and forth but never use too much force. Once the bolt turns, even a little, you can get it out if you take your time.

I parted a bike one time and the exhaust bolts were seized. If you take a wrench and try to turn them out, every one would break. As an experiment I did as noted above and managed to get four in a row out. Took some time, but got each one. Ham fist the job, and you are screwed.

[TheCafeKid]

A couple of other things I would suggest (besides Eds observation that one should use a penetrating oil instead of a water dispersant oil like WD40, which I WILL add makes a great neutral cleaning agent for heavy grime build up on painted parts..but that and it's original use are about all it's good for IMO) is once you DO get them out, either swap to studs with nuts, or use some antiseize compound if you put them back in. Heat and two different metals do weird things, which is why they're often stuck like chuck in the heads.

Here's a good one for ya... My brother was once helping install a set of pipes and broke a bolt off going IN.... Man... I had to walk away...

[1980GS1000E]

Same thing happened to me. And then I broke the bolt extractor off in it. Don't use a bolt extractor if you can avoid it. I wound up just drilling and drilling.
See this thread:

http://www.thegsresources.com/_forum/showthread.php?t=169521