Yes enjoyed the video very good thanks, I think the skill level is beyond me, might have to get the pros on my FZ6 can see me snapping bolts off!!! Good job I saw this! Thanjs
Penitrating fluid & a blow torch is your best friend dealing with exhaust headers i've found out. Also, a lew NM tourqe gun. Works a charm to shake lose all that rust, if you see alot of rust already on the bolt don't even atempt to remove. More then likely it's seized onto the stud. Better to get penitrating fluid. I'd run the bike before hand get it nice & hot. Then spray it with your fluid, leave to sit for a few mins & try to remove your bolts. Should come off pretty easily.
I felt your pain, I am having the same fun with my zx7r. Why do they make the studs so short? once you get the new ""thicker"" gasket in place, its almost impossible to get the nuts on!
This is a job that you just cant rush! I was confronted by the same problem removing my exhaust to get the collector box joint repaired (Thank you Bandit Mania, www.banditmaniashop.co.uk/) I also had to tap a hex into the bolts to make them go in they were so rusted but this gave them a bit more grip! Patience is key when undoing bolts like this. First soak them (and I mean SOAK!) them in a good penetrating fluid or WD40 the night before or as long before as you can manage, and start undoing the bolts just a little at a time. If they begin to move, then tighten up, do them back up again and do this each time they tighten up when you try to undo them again. The back and forth motion breaks up the rust in the thread and the application of more penetrating fluid will help the bolts come out cleanly. Patience is the key here as rushing will only result in what you see in this video. I got all my bolts out without any breakages, without damaging any threads and without having to resort to heat (it's easy to melt Ali head fins with a blowtorch!!) but it did take me just over an hour to do. You cant rush it!! Also, having to knock in a hex socket into the bolts due to the rust with a light/medium weight hammer (no need to wallop it! you'll just damage the heads!) actually helped to break the rust up a little and shock the bolts loose even though they were still reluctant to let go. Just Take your time and you will get them out with no drama! Plus having 30+ years of engineering experience helps!! :-) Maybe I should have made my own video of this...
Hi. The short video is quite obviously not filmed continuously. I actually spent much longer than an hour turning the bolts ever so slightly. Its a good point to note too that these Allen screws were made of Stainless, which of course i'm sure you are aware (30 years in Engineering), has a chemical reaction with the Aluminium engine casing. The previous owner, when installing the exhaust possibly forgot to, or didn't put enough anti seize paste/ copper slip on. I appreciate your 'comment' however, not for myself, i have quite literally been there done that, which i thought was obvious above? There will likely be other people trawling the web for the best way and there, i'm sure they will find your advice. Thanks
I apologize if you think I was a little patronising but the way you attacked that bolt was a bit heavy handed. As soon as it tightened up to the point that extreme force was necessary to turn it any further, you should have stopped and turned it back the other way to ease the bond with, perhaps, another squirt of WD40! I never know why bike and car (or any other vehicle) manufacturers insist on fitting steel bolts into aluminium castings as they must know what's going to happen and they rarely, if ever, use an anti-sieze agent. We, at work, dont! we fit helicoil inserts as we know in the racing industry these bolts are often undone and re-tightened on a very regular basis! Just out of curiosity, How many miles had the bike done before you had to remove those Bolts?
You drill down the stud, getting wider and wider until you can scrape out the remaining pieces of stud. That way you keep the original thread. Beware, if you drill the thread out you might need to use a helicoil. If you drill off to the side you might end up going into the cylinder head's body and therefore you are in BIG trouble.
Use socket (headed) bolts???? who in their right minds????!!!!!! Whoever uses bolts in a head needs their head examined! USE grub screws & aerotight nutz. I only use stainless grub screws (m8 x 50mm in my case) & stainless aerotight nutz. Use plenty of alumaslip/graphite based antisieze (not coppaslip in aluminum threads). Maybe one person will find this comment and nod their head! And, yeah getting that broken bolt out would require heat and patience. There looked enuff sticking out and with heat and patience. Outer bolt got jammed because the inner bolt was still tightened pressing the inner side of flange and the outer side of flange was jamming against the outer bolt as it was trying to spring outwards. Thus the shear.
you did,nt break the bolt from lack of experience , i,ve been doing bike engines since i was 12 and im now 50 ,and trust me .if a bolt is gonna snap ,it,s gonna snap ,no matter how experienced you are . you can heat up with oxy or a blowtorch and they will just snap anyway,if your lucky they come out with heat,but that does,nt always happen ,there always that one ,no matter what you do ,that will snap ,drilling them out is the last resort ,i would use a mig welder first ,seeing as you a small piece of thread sticking out ,you could weld a nut to it .
Just going through same problem 1 bolt snapped in luckey for me a lot of heat and patience paid off and got the bolt out
Yes enjoyed the video very good thanks, I think the skill level is beyond me, might have to get the pros on my FZ6 can see me snapping bolts off!!! Good job I saw this! Thanjs
Penitrating fluid & a blow torch is your best friend dealing with exhaust headers i've found out. Also, a lew NM tourqe gun. Works a charm to shake lose all that rust, if you see alot of rust already on the bolt don't even atempt to remove. More then likely it's seized onto the stud. Better to get penitrating fluid. I'd run the bike before hand get it nice & hot. Then spray it with your fluid, leave to sit for a few mins & try to remove your bolts. Should come off pretty easily.
I felt your pain, I am having the same fun with my zx7r. Why do they make the studs so short? once you get the new ""thicker"" gasket in place, its almost impossible to get the nuts on!
This is a job that you just cant rush!
I was confronted by the same problem removing my exhaust to get the collector box joint repaired (Thank you Bandit Mania, www.banditmaniashop.co.uk/)
I also had to tap a hex into the bolts to make them go in they were so rusted but this gave them a bit more grip!
Patience is key when undoing bolts like this.
First soak them (and I mean SOAK!) them in a good penetrating fluid or WD40 the night before or as long before as you can manage, and start undoing the bolts just a little at a time.
If they begin to move, then tighten up, do them back up again and do this each time they tighten up when you try to undo them again.
The back and forth motion breaks up the rust in the thread and the application of more penetrating fluid will help the bolts come out cleanly.
Patience is the key here as rushing will only result in what you see in this video. I got all my bolts out without any breakages, without damaging any threads and without having to resort to heat (it's easy to melt Ali head fins with a blowtorch!!) but it did take me just over an hour to do. You cant rush it!!
Also, having to knock in a hex socket into the bolts due to the rust with a light/medium weight hammer (no need to wallop it! you'll just damage the heads!) actually helped to break the rust up a little and shock the bolts loose even though they were still reluctant to let go.
Just Take your time and you will get them out with no drama! Plus having 30+ years of engineering experience helps!! :-) Maybe I should have made my own video of this...
Hi.
The short video is quite obviously not filmed continuously. I actually spent much longer than an hour turning the bolts ever so slightly. Its a good point to note too that these Allen screws were made of Stainless, which of course i'm sure you are aware (30 years in Engineering), has a chemical reaction with the Aluminium engine casing. The previous owner, when installing the exhaust possibly forgot to, or didn't put enough anti seize paste/ copper slip on.
I appreciate your 'comment' however, not for myself, i have quite literally been there done that, which i thought was obvious above?
There will likely be other people trawling the web for the best way and there, i'm sure they will find your advice.
Thanks
I apologize if you think I was a little patronising but the way you attacked that bolt was a bit heavy handed. As soon as it tightened up to the point that extreme force was necessary to turn it any further, you should have stopped and turned it back the other way to ease the bond with, perhaps, another squirt of WD40!
I never know why bike and car (or any other vehicle) manufacturers insist on fitting steel bolts into aluminium castings as they must know what's going to happen and they rarely, if ever, use an anti-sieze agent. We, at work, dont! we fit helicoil inserts as we know in the racing industry these bolts are often undone and re-tightened on a very regular basis!
Just out of curiosity, How many miles had the bike done before you had to remove those Bolts?
how we're the retainer gaskets on 1&4 pipes intalled?
installed exactly how they were dismantled mate.
Whats about the broken bolt ? The exhaust is leaking there ?
yes
The same thing happened to me! with the exact same bolt! how did you fix it??
Says it in the vid mate. Basically, drilled out little at a time so not to damage threads. Needed a good drill bit and a steady hand
MindfulExplorer how much did Ross charge you?? I need someone to do it for me and I'm near Sheffield
He's just moved HTC to Doncaster now. You should ask him how much he'd charge, I can't remember. not much.
@Gee Smith Im also near Sheffield and I have a snapped exhaust stud in my R6 im in York
Try a gas blow lamp on the 6mm bolt...then try if it goes tight reheat it
So...?? What happened.. How did you fixed?? 🙄
You drill down the stud, getting wider and wider until you can scrape out the remaining pieces of stud. That way you keep the original thread. Beware, if you drill the thread out you might need to use a helicoil. If you drill off to the side you might end up going into the cylinder head's body and therefore you are in BIG trouble.
Coloured text is a bit naff Mate. The white is much easier to read, 'specially on the dark background.
Would warming the bike up first help I need to take mine out of 2007 1200s and after watching this I'm shit scared
Have gave this a go myself and gave up.
i left it to the pros.
Someone has a halfords advanced set
Use socket (headed) bolts???? who in their right minds????!!!!!! Whoever uses bolts in a head needs their head examined! USE grub screws & aerotight nutz. I only use stainless grub screws (m8 x 50mm in my case) & stainless aerotight nutz. Use plenty of alumaslip/graphite based antisieze (not coppaslip in aluminum threads). Maybe one person will find this comment and nod their head!
And, yeah getting that broken bolt out would require heat and patience. There looked enuff sticking out and with heat and patience. Outer bolt got jammed because the inner bolt was still tightened pressing the inner side of flange and the outer side of flange was jamming against the outer bolt as it was trying to spring outwards. Thus the shear.
you did,nt break the bolt from lack of experience , i,ve been doing bike engines since i was 12 and im now 50 ,and trust me .if a bolt is gonna snap ,it,s gonna snap ,no matter how experienced you are . you can heat up with oxy or a blowtorch and they will just snap anyway,if your lucky they come out with heat,but that does,nt always happen ,there always that one ,no matter what you do ,that will snap ,drilling them out is the last resort ,i would use a mig welder first ,seeing as you a small piece of thread sticking out ,you could weld a nut to it .
Mine r worse 😭😭😭
You'll do it mate.
They won't undo did u remove the radiator