well this sucks

[jbayreaux]

Okay, what a bad time I am having, my laptop was stolen, my home pc is screwed up by a virus, and now I broke an exhaust bolt. I read in these forums of PBblast. I forgot who it was, but he said that he sprayed the bolts for 3 days leading up to their extraction. I did so on the remaining bolts and like butter all three came out. Now, on my remaining broken bolt, it did not have enough stud to work with. I tried to make a groove with a dremmel as to take it out with a flat head skrewdriver, nothing. I tried to turn it with a hammer and chisel, nothing. So,.... I bought a new set of drill bits. And drilled the f'er out. I got it to where I saw threads, and I could not get the peices out. Whats worse, I actually DRILLED the threads out. I swear, someone shoot me now. Life could be worse, but this just sucks. I know my computer situation is shot..... But could anyone give me some advise in regards to my GS? I dont have enough money to pay someone to change my cylinder heads, so could I salvage my threadless exhaust bolt hole somehow?

[ddaum]

Go to your local True Value or similar hardware store and talk to someone about a metric helicoil insert. You'll need to buy a tap & die kit to re-tread the hole. OR, you might be able to just carefully drill out the remaining threads and tap the hole to fit the next size bigger bolt.

[nabrams]

Yeah, if you got as far as drilling the bolt out (that's the most time consuming and annoying part) then the heli-coil should be a no-brainer. You're lucky it wasn't one of the bolt holes which are impossible to drill out with the head still on the bike. Just follow the instructions carefully and read my other posts (and other people's as well) on this subject. I've done this more times than I care to remember. Proceed with care and it should work out fine.

[Baatfam]

Autozone sells a heli-coil clone kit that has the tap included....
Works well, I've done a dozen 6mm heli-coils on the dragbike...

Bob T.

[jonr]

I did 3 or 4 heli-coils on the 750 and they were 8mm bolts. The damn kit cost me $30, but at least it worked like a charm. I had a few where the frame blocked the head, but all I had to do was remove the motor mounts and jack up one side of the engine with a small pnematic jack (wooden plank between jack head and oil pan). This tilted the motor enought for me to get a straight shot at the broken stud.

good luck-
J

[louisciccoli]

If you already have a tap set you can call a company called EZ Lock.They are somewhere in the L.A. area if I recall correctly, they make thread inserts that are similar to helicoils. I got their info from a search on the web when I ruined the spark plug hole for my GS1000.To top off the fact of ruining the hole I also drilled it out too large for a standard insert,however they make an oversized insert for the same size plug. I founr it very easy to use. They sent me a single insert for free. It was just what the Dr. ordered, however as I said earlier you have to have a tap set to use with it. As everybody else said drilling the hole is the hardest part but make sure you have the right size hole to go with whatever method you decide to use as it is fairly critical for the tap. Good luck

[Nessism]

There's not a lot of meat around the bolt holes on the GS450 head so be careful when drilling the head for an insert. I bought a used off ebay when restoring my 450 and the exhaust bolt threads were stripped. Worse yet was that some bonehead drilled out the bolts off center which rendered the head junk because there was not enough room left to repair the threads.

Good luck.

Ed

[Clone]

If he's on a budget, just tap it out to the next size bigger bolt, cost of a tap $.99 new stud and nut and washer $.20. Problem solved for a buck and a quarter.