Frozen exhaust bolts

[Guest]

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?

[5azzmonkey]

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?

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

-Dave

[gustovh]

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

[Nessism]

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.

[londonboards]

This is what I did:

http://suzukigs1100.blogspot.co.uk/2012/10/exhaust-bolts-out-day-55.html

Take your time.

Greetings

[Scratcher09]

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?

[Nessism]

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?

Can't believe you are even asking this question. Yes you should! Use some good antiseize on the bolts before installing too.

[tkent02]

Use stud and nuts. Don't be cheap just because Suzuki was.

[GSX1000E]

Don't forget to re-tap or chase those threads in the head too.

[Scratcher09]

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.

[tkent02]

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.

[Scratcher09]

Is there a certain grade required for the stud or bolt? Can I find these at Home Depot?

[tkent02]

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.

[Scratcher09]

I'll look at Napa tomorrow. Thanks.

[koolaid_kid]

I get mine at Ace H/W.