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broken head bolt

  • Thread starter Thread starter jlbendall
  • Start date Start date
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jlbendall

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I have a broken head bolt on my 1980 GS550 I need to remove the motor from the frame to extract the bolt. Removing the motor seems easy. 1. Remove the cables, carbs and chain, then mounting bolts. Anyone ever had any surprises removing the motor?
 
the weight can be a surprise, be prepared in case it falls.

why do you need to remove the engine?

once when one of mine broke i removed enough to leave an inch showing on the bolt, then after covering everything i ground a flat either side of the bolt and spannered it out
 
The bolt is broken of flush on the front tab and I can't get a drill around the frame.
 
never had a gs engine out, although they look straightforwars i would guess they are heavy, ive had a number of honda engines in and out and although its possible on your own i would enlist the help of someone fairly strong.

putting it back in can be more dificult, holding it in place while you locate the bolts etc.

would removing the head expose enough to get some grips around it?
 
I feel your pain because I've been through that myself.
The GS450 head can come off without removing the engine from the bike (not so for my Honda CB750 - which I had to remove the engine in order to replace a blown head gasket!!!).
You'll probably have to go through the drill/tap/helicoil routine. See the many posts on this topic.
 
nabrams said:
I feel your pain because I've been through that myself.
The GS450 head can come off without removing the engine from the bike (not so for my Honda CB750 - which I had to remove the engine in order to replace a blown head gasket!!!).
You'll probably have to go through the drill/tap/helicoil routine. See the many posts on this topic.
Click to expand...


the remaining bolt shaft may make it impossible to get the head off in situ as you would have to lift it much higher to clear the bolt.

once access is gained to the bolt shaft grinding flats to accomodate a spanner will at least give a chance to avoid further problems from helicoils
 
nabrams said:
I feel your pain because I've been through that myself.
The GS450 head can come off without removing the engine from the bike (not so for my Honda CB750 - which I had to remove the engine in order to replace a blown head gasket!!!).
You'll probably have to go through the drill/tap/helicoil routine. See the many posts on this topic.
Click to expand...


hmmm not sure why you couldnt get your head off tho, ive managed it on a 750, it is tight though, then cylinders are even tighter!!
 
You managed to get the head off a 1982 HONDA CB750, without removing the engine from the frame?
I'd like to know how you managed that!
 
I got the bike of of E-bay as a project only paid $250.00 for it so I am still ahead. the the seller said it had an oil leak but did not know how to fix it. so I took a chance. if I can get this problem taken care of, it will be ready for the road this summer.
 
when torqued up after time they kinda lock in place, i think they are designed with some kind of stretch built in which is why they are supposed to be replaced when removed

you can hear them cracking quite loudly when you break the pressure of, this is how i snapped one, it was relatively easy
 
nabrams said:
You managed to get the head off a 1982 HONDA CB750, without removing the engine from the frame?
I'd like to know how you managed that!
Click to expand...

dont know if it was an 82 but i think the engine was very similar if not the same, remover rocker covers, cams, headbolts etc then lift and bend the tensioner clear undereneath

didnt seem that difficult at the time, i think the biggest challenge was clearing the rocker cover
 
jlbendall said:
The bolt is broken of flush on the front tab and I can't get a drill around the frame.
Click to expand...
Are we talking about the small 6mm bolt at the front of the motor, right in the center, inline with the cam chain tunnel ??? .......If you are, it is a "through" bolt, which means it goes all the way through the block and is visible from underneath...... If this is the case, I would opt to pull the motor and drill through the head and block with a 1/4" drill bit....This will allow you to put a nut/bolt in the hole and tighten to spec.....If it still doesn't seal the oil leak, you will probably have to pull the head to replace the rectangular "o" ring seal and head gasket....At this time you could put a heli-coil in the block very easily.......I would much rather try to fix a problem like this without pulling the head and block if at all possible.....Pulling the head will not give you much more access for drilling the broken bolt in the block if the motor is still in the frame.....This is assuming you are talking about the front "bowtie" bolt........BadBillyB
 
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