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Author Topic: Busted exhaust bolt - any ideas  (Read 547 times)

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popag

  • Old Timer
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  • Posts: 136
Busted exhaust bolt - any ideas
« on: April 04, 2011, 07:30:55 AM »

While tearing the bike down to clean polish and replace parts a couple of parts for some reason I couldn't stop so I kept replacing one thing after another since I ordered them and are sitting there. Anyway long story short I was taking the exhaust bolts off and one was very hard to turn. I can see whats coming, so I stopped and squirted some penatrating oil and ran the bike to heat it up a bit. Turned it a couple of times and sure enough the stud snapped in half on the rear exhaust port.

Does anyone have any ideas on possibly getting this stud out? Any help is appreciated.
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'03 VTX 1300S Retro
Texas Sons Of Liberty Rider
http://texassonsoflibertyriders.ning.com/

zerogs

  • Tejano
  • ***
  • Posts: 61
  • 2003 VTX 1800C R.I.P. Torque
Re: Busted exhaust bolt - any ideas
« Reply #1 on: April 04, 2011, 01:09:03 PM »

 :ohwow:  that sucks. I have broken several bolts but not any on the bike. What works for me does not work for some people but you can give it a try if you have the tools that I usually use to do it.
A dremmel to grind the broken bolt surface as smooth as possible
center punch get a dent in to start a drill bit
retract kit choose the drill bit and retract tool that fits (about half the size of the broken bolt). drill about 1/8 deep or slightly deeper if possible and use the retract to reverse drill it out.

 to warm up the bike before doing it i dont know if it will help or not. sometimes it does and other times it dont but for sure wd40 it and let it soak a little around the edges

Not sure how much the retract kit cost these days, i have had mine for over 10 years and broken a few during some attempts but it works for me. I need to go get a new set myself. best of luck hope it works for you or some one else has a better or easier way to do it.
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Imagination is the Elixar to life.
Rest in Peace Jacob A.K.A. Torque
12/18/1975-4/29/2009

RedDragon

  • Master of Monumental Proportions
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Re: Busted exhaust bolt - any ideas
« Reply #3 on: April 04, 2011, 07:31:06 PM »

Just don't break the easy out!  :popcorn: Then you have to go to the diamond bits.   :cuss: Right Gabe!  :c
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2005 VTX 1800C Red Tribal Flame
2005 Yamaha FZ1 Silver

hooter

  • Master of Monumental Proportions
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  • Itasca (just North of Hillsboro on sceanic I-35W)
Re: Busted exhaust bolt - any ideas
« Reply #4 on: April 05, 2011, 07:45:53 AM »

Sure ain't sounding good for the home team.  :banghead: :ohwow: :redcard: :redcard:
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