Broken exhaust screws

[Audioslave784]

I've got three exhaust screws with broken heads stuck in the engine of my 1980 850L. They are all more or less behind the frame, so a screw extraction cannot be done on the bike.

I can think of three options for getting these out:

1) Remove the whole engine from the bike and extract the screws

2) Remove just the top end from the engine and extract the screws

3) Remove the top end from the engine and replace it with the one from another 850 engine (which I happen to have)

Now I've never opened up an engine or removed one from a bike, so I was wondering what you guys thought the easiest option is and how exactly this would be done?

[chuck hahn]

How much of the bolt is sticking out or are they broke off flush? I snapped one on my 77 750 and there was enough sticking out that i put a nut over the threads sticking out and welded it on. I then sprayed it with PB blaster and let it set a while..came right out.

[tkent02]

Are the broken bolts flush, recessed or sticking out?
Can you weld?

[posplayr]

I've got three exhaust screws with broken heads stuck in the engine of my 1980 850L. They are all more or less behind the frame, so a screw extraction cannot be done on the bike.

I can think of three options for getting these out:

1) Remove the whole engine from the bike and extract the screws

2) Remove just the top end from the engine and extract the screws

3) Remove the top end from the engine and replace it with the one from another 850 engine (which I happen to have)

Now I've never opened up an engine or removed one from a bike, so I was wondering what you guys thought the easiest option is and how exactly this would be done?

No point in doing the top end unless it needs it ; or you have a base gasket leak (like me). If you do need to pull the head put the best head back on .

Bottom line is pull the head based on the enginer need not the broken bolts. Truely the easiest of the three is to pull the engine (drain the oil first)