I did it. Broke an exhaust flange bolt.

[1980GS1000E]

A follow up-

I was very lucky on this-

You can see what's left of the offending bolt, the tip of the busted e-z out, and the punch that I used to hammer it through the bolt:

And here is the hole in the head:

It is only buggered up for about 3/8 of an inch or so, then the threads are good. Now I will get some stainless studs and fix this thing. You guys are so correct about using e-z outs. Don't do it.

 

[Guest]

Great work! Sure you feel alot better with that bolt out. It's stories like this that allow me to keep my "New To Me" GS1000 stock mufflers in the
unopened box they came in last summer.

 

[duaneage]

Run a proper tap through the hole to clean the threads up and remove any hangers. Also good for getting clean metal to secure the stud with. I loctited mine in with blue loctite.

 

[1_v8_merc]

I think I'm going to buy a spare Head from a bike-yard, JUST so I can avoid this ****....
I just know I'm going to break every bolt on my 650.

Stupid jap-crap bolts.

 

[1980GS1000E]

Run a proper tap through the hole to clean the threads up and remove any hangers. Also good for getting clean metal to secure the stud with. I loctited mine in with blue loctite.

I chased them with a craftsman tap, the size is 8 x 1.25. Didn't know what I should secure them with, blue loctite you say?

 

[Road_Clam]

I chased them with a craftsman tap, the size is 8 x 1.25. Didn't know what I should secure them with, blue loctite you say?

Loctite will not work correctly on the head. Loctite when heated actually softens up considerably. I actuallu antisiezed all the bolts on my 1100 so as to ensure easy removal in the future...

 

[1980GS1000E]

Well, I just am not comfortable with the stock method at all. Studs are the way to go.

 

[Nessism]

There are high temp grades of thread locker, but thread lock isn't needed as near as I can tell. I use anti-seize on exhaust bolts.

 

[koolaid_kid]

There are high temp grades of thread locker, but thread lock isn't needed as near as I can tell. I use anti-seize on exhaust bolts.

I agree on both points. Use anti-seize. If you don't have any, the auto parts will probably have a $0.99 packet at the counter. I keep a small bottle myself, because I use it on spark plugs on all my vehicles.

 

[Ranger]

I agree on both points. Use anti-seize. If you don't have any, the auto parts will probably have a $0.99 packet at the counter. I keep a small bottle myself, because I use it on spark plugs on all my vehicles.

They have tape now too from loctite...

 

[1980GS1000E]

Happy now..

Happy now..

I am happy to say that problems like this should now be a memory. I encourage every Suzuki rider who has taken their pipes off to do this mod. It is the norm for Yamaha, Kawasaki, and Honda.

 

[duaneage]

The kit from NAPA has a 5 mm hex nut on the end for installation as well. I think Suzuki was one of the few if not the only major player to use bolts out there.

 

[posplayr]

A happy ending to this tragic story;

It was paining me to think about you having to pull that head just to get the broken bolt out.

I use stainless hex bolts with anti-seize. Also never take them out because I have spigot

 

[Dodik]

im actually in the similar boat now where PO broke drill bit/extractor in one of the bolts about 1/8-1/4 from the surface so machine shop will take care of that but i where did you get studs from?

 

[cowboyup3371]

You can pick them up from your local hardware shop. I got mine from Ace at a decent price.

 

[1980GS1000E]

I got mine from Fastenal, a store nearby.