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Frozen exhaust bolts

  • Thread starter Thread starter Scratcher09
  • Start date Start date
S

Scratcher09

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Three of my exhaust bolts will not budge. I sprayed them with PB Blaster and still can not get them unstuck. I once snapped an exhaust bolt flush with the surface and it was very difficult to remove so I want to avoid that. Any ideas as to how I can remove them without breakage?
 
Scratcher09 said:
Three of my exhaust bolts will not budge. I sprayed them with PB Blaster and still can not get them unstuck. I once snapped an exhaust bolt flush with the surface and it was very difficult to remove so I want to avoid that. Any ideas as to how I can remove them without breakage?
Click to expand...

Try the search function. There are plenty of posts regarding this subject with great tips.

-Dave
 
propane torch, heat the aluminum around the bolt with a propane torch while applying pressure with your wrench, the aluminum expands before the steel of the bolt.
V
 
Better to heat the bolt. Red hot. Get some PB Blaster to wick into the threads and break down the corrosion. Turn the bolt both in and out using a small 1/4" ratchet. Use too much force and the bolt will snap off. Once you get it to turn a little, use more spray and more heat. Work the bolt both ways, in and out, but don't force it.
 
Thank you for the advise. The PB Blaster, heat, and slow rocking back and forth did the job. Got all out without any breakage. Should I replace the bolts with new ones?
 
Scratcher09 said:
Thank you for the advise. The PB Blaster, heat, and slow rocking back and forth did the job. Got all out without any breakage. Should I replace the bolts with new ones?
Click to expand...

Can't believe you are even asking this question.:eek: Yes you should! Use some good antiseize on the bolts before installing too.
 
Don't forget to re-tap or chase those threads in the head too. ;)
 
Nessism, I believe the only stupid question is the one that doesn't get asked. Isn't the purpose of this forum to share knowledge with each other? Maybe I should apologize in advance because I will likely ask more ignorant questions as I get deeper into this project.
 
Those bolts get weaker and weaker with heat cycles and age. I just snapped a couple off with almost no twisting, just easy turning. It was coming out, it then got stuck just a tiny bit, snap! Replace them with good quality studs and nuts, you can use acorn nuts if the appearance is important to you. Put them on with anti-sieze and don't over torque them. NAPA sells a nice set of eight M8 x 1.25 studs and nuts for $7 or so. There's even a little hex head on the end of the stud.

I'd pull them out and redo the anti sieze every ten years or so if I was keepingthe bike forever.
 
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Is there a certain grade required for the stud or bolt? Can I find these at Home Depot?
 
Don't know, M8 x 1.25 is the size, length is up to you. Some people use stainless steel studs, I don't as stainless can get brittle. That NAPA kit uses good quality bolts and is priced well. Home Depot is super expensive for any metric fasteners. I'm sure Fastenall woud have something.

I suppose with enough anti seize even crappy bolts would come out OK next time.
 
Use a cleaning tap Not a regular tap. I had the length written in my book as 50mm
 
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