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Help broken/frozen exhaust manifold bolt (with pics)

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  • #1

    Help broken/frozen exhaust manifold bolt (with pics)

    I was taking off the exhaust to patch some holes and one of my bolt heads snapped clean off another two of the heads spun off.

    https://goo.gl/photos/Ge8PcaZMTsrxP2yL7

    so I have three manifold bolts stuck in the block total one snaped off and two whole. so far I've tried, cutting a slot and using an impact driver, heating with a small butane torch, and crc freeze off. The broken bolt has no threads the other two are just very rusty
    • How do I get these bolts out?
    • Being that I'm not experienced in removing frozen bolts is it best to bring it to a shop and have them remove the bolts?
    • What would it cost to have those bolts removed at a shop?
    • I bought new bolts but haven't been able to find the nuts what is a suitable replacement?
    • I also snapped one of the crossover circle clamps what is a suitable replacement for those?
    • anyone in the Long island area interested in helping get these damn things out?
    • Is there any way i could still drive it to a shop without that one bolt secured?(shop is roughly a mile or two away)


    Thanks!
    79 F Bobber/Cafe Hybrid
    Rasputin on Carburators:
    "It is just a mechanical beast that defies logic."
    Tags: None
  • #2
    Here you go!

    Broken Stud Removal Techniques.mp4
    Marty (in Mississippi)
    XS1100SG
    XS650SK
    XS650SH
    XS650G
    XS6502F
    XS650E

    Comment

    • #3
      Originally posted by jetmechmarty View Post
      Here you go!

      Broken Stud Removal Techniques.mp4
      do you know what that tool is called and where I could get one?
      79 F Bobber/Cafe Hybrid
      Rasputin on Carburators:
      "It is just a mechanical beast that defies logic."

      Comment

      • #4


        Titan Stud Puller - 3/8in. Drive, Model 16023



        http://www.northerntool.com/shop/too...5363_200385363
        Marty (in Mississippi)
        XS1100SG
        XS650SK
        XS650SH
        XS650G
        XS6502F
        XS650E

        Comment

        • #5
          That's a sexy tool. Will be adding that to my tool box.
          1979 XS1100F
          2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

          Comment

          • #6
            Originally posted by IanDMacDonald View Post
            That's a sexy tool. Will be adding that to my tool box.
            That what she said !!!
            1980 XS1100G "Dolly G" Full Dresser (with a coat of many colors )
            1979 XS1100SF (stock-euro mods planned)
            1984 XV700L Virago (to be hot-modded)
            1983 XJ750MK Midnight Maxim (semi-restored DD)
            1977 XS650D ( patiently awaiting resto)

            Sometimes it takes a whole tank of gas before you can think straight.

            Comment

            • #7
              I want one of those..

              Bill
              1980 XS1100 SG
              Jardine Spaghetti with Harley Mufflers

              Comment

              • #8
                In places that have good access, you can just us the drill chuck...most of the time for the small studs (6mm or so) Milwaukee cordless has plenty of torque, sometimes I help it along by twisting the chuck by hand as well.

                I also use it to remove dowel pins/etc. works great without damaging them if you do not over tighten the chuck.

                Comment

                • #9
                  I tried the tool suggested in this post and it only made the situation worse now I have two broken studs. Going to try and drill it out today but probably destined for the shop tomorrow.
                  79 F Bobber/Cafe Hybrid
                  Rasputin on Carburators:
                  "It is just a mechanical beast that defies logic."

                  Comment

                  • #10
                    For your short broken exhaust stud I'd slide a bigger nut over the stud and weld it on, the heat helps release the stud from the ali head and the nut allows a socket to turn it. IF you access to a welder.
                    Tom
                    1982 5K7 Sport, restored to original from a wreck
                    1978 2H9 (E), my original XS11, mostly original
                    1980 2H9 monoshocked (avatar pic)http://i145.photobucket.com/albums/r...psf30aa1c8.jpg
                    1982 XJ1100, waiting resto to original

                    Comment

                    • #11
                      Just a thought...

                      Just a thought...

                      While you have plenty of room to work, give a thought to changing the old style camshaft chain tensioner to an automatic one...

                      The stock one is not very reliable and if it should fail while the engine is running, it could turn into a mess...

                      Just a thought...

                      The Tenorman
                      Last edited by Tenorman; 07-06-2015, 08:05 AM. Reason: Error
                      Bikes that I have owned and enjoyed...
                      1964 Allstate 250
                      1970 Yamaha DT1
                      1959 Mobylette
                      1970 Yamaha JT1
                      1995 Suzuki 80
                      1978 Yamaha XS650
                      1980 Yamaha XS1100LG
                      2005 BMW R1150R

                      Comment

                      • #12
                        I actually bought one a while ago and havent installed it might be a good idea. The shop want to charge me between 2-300 just to get the manifold bolts out out Im a litle worried about taking the cylinder cover off and snapping more bolts.
                        79 F Bobber/Cafe Hybrid
                        Rasputin on Carburators:
                        "It is just a mechanical beast that defies logic."

                        Comment

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