header bolt question

[kparkfan]

Ok I posted a few days ago that I had snapped a bolt off for the exaust. I have tried everything I can to get this darn thing out with no success. Will it hurt running the bike with one missing bolt till this winter when I plan on taking my bike over to TCK'S ( JOSH) to tear it down and do some things to it. One of the things I'm planing on doing is the head gasket at which time I can take the head to a machine shop to have the bolt removed.

Also does any body have any idea about how much they generally charge for something like that?

[kparkfan]

Well I'll take it that 13 people have looked at this thread but no replies that it wont hurt to run it like this.

[hikermikem]

I don't think it will hurt anything - the downside is you might have an exhaust leak at that clyinder. Feel around there with your hand & listen for it.

No biggie IMHO... sounds like a good plan to wait until you were going to pull the head anyway.

I paid my friend $10 to remove my broken exhaust bolt by welding to it & then turning it out. That method would be my choice before the machine shop routine...

[Nessism]

You most likely will be ok with one missing bolt but check your plugs to see if the cylinder is running lean - suck air into the combustion chamber.

My guess is about $30 to extract the broken screw. I suggest you have them check the head for surface flatness, along with the cylinder, and have them cut if they are not flat to within .005". The composition type head gaskets can take more misalignment that the MLS type so the flatness you need will depend on the type of gasket. Also, plan on replacing the valve stem seals and consider rings and hone job as well if the engine has more than 25k miles on the engine (my opinion anyway).

[kparkfan]

Sweet thanks guys. I have another question for you all. On the 2 inner pipes there were little half moon shaped metal pieces on them. what are these for and why are they only on the 2 inner pipes?

[hikermikem]

Sweet thanks guys. I have another question for you all. On the 2 inner pipes there were little half moon shaped metal pieces on them. what are these for and why are they only on the 2 inner pipes?

Those pieces fit around the portion of the pipe that goes into the exhaust port (2 half-moons per pipe), with the lip side sticking out. The finned ring then butts against the lips & pushs the pipe into the port when you tighten the bolts.

All four pipes should have the half-moon thingys

[kparkfan]

Hmmm they only had them on the 2 inner pipes.

[TheCafeKid]

Hmmm they only had them on the 2 inner pipes.

They only have them on the inner two. The flanges cannot be removed from the 1 and 4 pipes, but the inner two can. They MUST be used, or it will not seal.

[kparkfan]

Cool i got them in there. Just want to make sure tomorrow that the #3 pipe dont leak without the other bolt in there.

[hikermikem]

They only have them on the inner two. The flanges cannot be removed from the 1 and 4 pipes, but the inner two can.

Geez, you'd think I would remember that, I just had that all apart on my 750 a couple of months ago...

Thanks for the correction Josh...

[67fire]

Not sure if this was mentioned earlier but, have you tried a "left-hand" drill bit to remove the broken stud?

Eric

[kparkfan]

I'm not sure that would even work. It is in there pretty good.

[chef1366]

I just got one out that was flush with the head. I center punched it and started with a small drill bit and worked my way up to one that that got a good bite with an Easy Out. Before using the Easy Out I heated the area around the broken stud for a few minutes. Came right out.

[salty_monk]

You could also drill it & tap it at 6mm, even 5mm to get you by. If it's sealed though then it will likely stay sealed till you get the head off etc. Check carefully.

Dan

[quexpress]

removing broken header fasteners

This is what I have done on my GV1200

http://forums.delphiforums.com/n/mb/message.asp?webtag=TAZZZ2U&msg=6379.17

I have also used this method a few weeks ago to repair a few bolts on the left engine cover.