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Broken exhaust flange bolts

  • Thread starter Thread starter GS1100GLMLA
  • Start date Start date
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GS1100GLMLA

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I broke off one of my exhaust flange bolts inside the cylinder head. How do I get it out? Has anyone done this before? I just bought this GS1100GL today and was trying to fix a leaky exhaust pipe that was loose and while trying to remove the bolt, it broke off. I wasn't even torqueing it that hard.
 
Did it break off flush? If so, it'll need to be drilled out. Helicoil kits are available to replace the damaged threads. Consider replacing ALL the old bolts while you have the chance. I replaced mine with stainless steel allen head cap bolts. Use anti-seize compound when you install the bolts.

Oh yeah, one more thing. Stuff a rag in the hole to prevent debris from flying into the motor while you do the drill out.
 
or if it is sticking out some, do what I did and weld on another bolt too it. My gs 1100 had one go bad on her when I did the v and H. I know some other good suggestions where thrown into that thread. Look for vance and hines. pipes. under search
 
Thanks for the replys. I broke it off inside the head. It is recessed about 1/8" inside. Makes me mad. Now I have to waste time figuring this out.
 
Can you say, "Machine shop." I knew you could. Trust me the $40 bucks to remove the studs will be worth the time saved and lessened agravation factor.
 
I did this when one of mine broke off flush:

Tom MLC said:
Did it break off flush? If so, it'll need to be drilled out. Helicoil kits are available to replace the damaged threads.
Click to expand...

But wish I had done this:

Clone said:
Can you say, "Machine shop." I knew you could. Trust me the $40 bucks to remove the studs will be worth the time saved and lessened agravation factor.
Click to expand...

You decide, but looking back on it I'd recommend the machine shop.
 
if that is all a machine shop would charge then I would opted for that. I know heli coils can be expensive and you need too take ur time, step down from a drill size too a drill size till your dead centered on. If you adventourous, you can over size it then drill out. and re tapp it. But I don't recomend that method. only as a last resort.
 
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