frozen header bolts

[almarconi]

In use, the impact driver can break a bolt with no warning. Applying force by hand gives the needed feedback.

My experience has been the exact opposite, every bolt I've ever broken was done by hand with a ratchet. Now,whenever I disassemble anything, I only use an impact wrench. Never had a problem since switching to an impact wrench. Its not the hammering from the impact that snaps fasteners but the twisting of the hand ratchet that snaps the bolts off. Usually by the time you feel anything the fastener is getting ready to break.

[Road Rash]

Fighting two broken header bolts, right now, and losing. Both bolts at number 2 cylinder. Soaked it in PB as well as an acetone/ATF mix and nothing. Went to heat them and my torch cylinder was empty. (DOH!). At this point, I have most of the material drilled out just shy of going into the threads. Unless somethin miraculous happens by payday, I'll be running thread inserts in. Man, those Time-Serts are pricey!

[londonboards]

You might be interested in my blog entry when I had the same problem:

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

Greetings

[1980GS1000E]

Congrats for you on those non-stock allen bolts. Everybody has their methods. I can see an impact driver working if the bolt isn't fossilized completely to the head. But I have seen busted bolts from impact drivers too.