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Trouble removing three broken bolts...

  • Thread starter Thread starter Spenray
  • Start date Start date
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Spenray

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So I picked up a $200 1983 GS650GL with a Katana style tank. The exhaust, once removed, split apart from years of rust and neglect. I'm looking at putting on a replacement exhaust with all new hardware but am having a hell of a time removing three bolts/screws that are far past useable. Any help/ideas would be greatly appreciated. You can see the damage for yourself below.....
 
Heat and an impact wrench if you can... The best option would be to torch it.
 
Weld a "handle" on what's left of the bolt, by drilling a hole in steel bar or flat stock, stick it over the bolt, and welding it on. This heat will loosen any rust, and the handle will provide leverage to twist the bolt back and forth, a little at a time. Go easy, that bolt is very soft and weak. I have heard applying wax to the bolt while it is still hot works wonders, as the wax will soak all the way into the threads. I have not tried this wax myself.
 
It looks like someone has already tried drilling it out, and the starting point is badly off-centre. That's going to make it difficult to try the same.

You have plenty of bolt sticking out, so I'd go for the welding method mentioned by tkent02. Barring welding a "handle" on (which may not leave you enough room to turn- tkent, your input here, please; how long a handle can freely turn past the frame/head?), you could instead weld on a nut on the threads.
 
buy some "Aero Kroil". Bright orange can.
soak it for an hour, tap with small hammer on the heads to help break it loose.
That stuff is amazing.
If that fails, grinding a little of the junk from the top of the bolts could help you get a drill centered easier.
 
Thank you all for the sound advice... I've attempted a "cold" weld with no luck and will be moving on to getting the three little buggers out next week via heat with a bernzomatic torch, aerokroil (thanks exdirtbiker) and locking pliers. Unfortunately, I don't have real welding equipment at my disposal and don't have the resources to have someone else do the job.
 
If you can trailer it to a welding shop, this is a trick i have used many many times on bikes and cars. I have my own MIG welder so it conveinent for me...... If the bolt is sticking out about 5 MM or so, then get a nut that the hole will slip over the stud and have them plug weld the nut to the bolt. This has many benefits..first it heats the chit out of that bolt and heat breaks the rust apart in the threads, it allows you to now put a socket wench and easlly and slowly try to back the bolt out. If it budges a little, you then squirt it again with the oil and work it back and forth to grind the rust up even more. Each time you try to extract it more and more. Be patient and work it around and it will come out.
 
And Rover...there are OIL GALLIES right behind some of the exhaust bolt holes...you had better be danged good and carefull drilling them.
 
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