exhaust bolts stuck

[sae3231]

I have a 82 gs1100l, I was trying to remove the exhaust to repair it and I broke three of the eight header bolts. There is between 1/4 and 3/8 inch of exposed bolt. What is the best way to remove them. Should I heat them up before I try a bolt extractor or will the steel bolt and aluminum head make this more difficult?

[phaeton]

Some things you can try is spray on a penetrating ion activated lube like Castle Thrust before trying to get em out, use a bolt extractor, try vice grips, or use an angle grinder to slot a slot in the bolt and use a screw driver.... shouldn't be THAT hard...

[yogib]

A good penetrent let them soak,try tightening just a bit and then try to loosen them.Sometimes just getting threads to move in any direction gets them moving in both.Don

[Jethro]

PB Blaster- that stuff is like gold, man.

[m in sc]

I have had good luck heating the head a bit with asmall torch to loosen any gunk in the threads and to swell the aluminum up a bit.
IF you have acess to awelder, i can't tell you how nice it is to tack on a nut and just back the sucker out with a socket. :-D

[lord1234]

I gotta vouch for PB Blaster...that stuff loosens stuck bolts like that's its job...(oh wait....)

[Road_Clam]

ANOTHER solid vote for PB Blaster. Luckily I had read ALL the horror stories about the imfamous "seized" exhaust flange bolts. I sprayed mine on a daily basis, and let them just sit for about 2 weeks. All my bolts came out with minimal force.

[lord1234]

once you get them out...put some antiseize on them....

[SqDancerLynn1]

Or just get some studs 8?x1.25x50mm

[jaberwok]

Oh the never ending pain of removing stuck or broken bolts... When I first got my bike (2001) I was in such a hurry that I sprayed a little WD-40 on the bolts and tried taking them right out.... bad idea as I broke 3 of the 4 bolt heads off in the head. Then I thought I could get the "EZ-Out" tool from Sears... what a misnomer (when used incorrectly ). Broke the EZ-Out off in the bolt stud... from here I had to take it to a shop have it drilled out and heli-coils put in. All-in-all about $85 for the job that could have been avoided had I purchased some good penetrating oil and taken my time.

I have since become a self proclaimed "master" at removing stuck bolts with the help of a good penetrating oil (another vote for PB Blaster) and patience. If a bolt is stuck do NOT force it, use the oil, take your time. 1/2 turn out, 1/4 turn in (lube it up), 1/2 turn out (that's only if it's sticks the whole way out) sometimes once they break free they come out with your fingers.

I have also had bolts act very funny (as if mocking me).... First it sticks like a sun-of-a-gun...work slowly at it... then snap there goes the bolt head... CURSE CURSE CURSE....when I calm down and investigate the damage what is left of the bolt twists right out with my hand.... I think the MC gods are toying with me :-D

Remember you cannot rush a good thing, and a bolt coming out in one piece is a good thing!!!

Been there, broken that, had to learn to fix it! Thanks GSR!!!

Good Luck!!!

[yogib]

Yeah that PB blaster is like MAGIC! POOF!!!!