02' warrior broken head pipe bolt

[gtpimp]

well heres the deal.. some idiot that owned this before me thought it was cool to put the stock exhaust back on reallly ****** so theirfore the first time i was rideing it the bolts loosened and it broke the one bolt right off the engine.. awesome sooo how can i do this, i have a new bolt and it catches a few threads still... im thinking filling that hole up with JB WELD or MAGNEM WELD and screwing the screw into that.. makeing it one and hopefully not breaking again. how does that sound.. heres a picture of the mess
CLICK TO ENLARGE!!!

 

[flyinacez]

Center punch that bitch real good, drill a hole and use an easy out bit. I had the same thing happen to me and it came out real nice!

 

[gtpimp]

is part of that stud still in there or what? i didnt think it was because i saw few sets of threads

 

[yamarider]

of course the stud is still in there! It broke off! If it didn't break off then you wouldn't be having a problem! I agree with flyinacez, hit it with a center punch and back it up with an easy-out.

 

[jstcriusen1]

Be very careful with the easy-out.! DO NOT break it off in there.

 

[flyinacez]

Ya if you do it will be off to the machine shop you go

 

[gtpimp]

yeahh well i ended up just drilling it right outta there and re-threading the hole with a bigger size, going to my local hardware store and getting a bolt and some lock washers since i couldnt find a stud so now she seems to be holdin up nicely

 

[flyinacez]

atta boy!

 

[DeathShadow]

Heat up the head around the bolt real hot with a MAPP gas/Oxygen torch (or another torch if u dont have one of these) and use vice grips to take it out.

Those exhaust studs break all the time because idiots try to crank away uber' ft-lbs on them on a cold head when they go to take the header off.

USE A TORCH IT IS YOUR BEST FRIEND!

 

[2xtreme]

I don't know why they decided to use studs for that anyway.

To me that's just stupid.

A good Hex head bolt would have been a better option. I think I am going to do that if/when I ever have to take the headpipe off.

 

[dave85zxt]

They used studs because you don't want to run bolts in and out of aluminum threads multiple times. Aluminum threads suck ass and cross thread/strip easily. All of the castings made at my work have heli coil inserts put in them. The threads would never last if they didn't.

I agree with Death on the heat idea. Another good idea is to soak the ******* in liquid wrench for a few days prior to working on them. It makes a huge difference.

My stud broke off too. I drilled it out and then used JB weld to repair the part of the casting that broke off too. Its held up for over a year now.

 

[2xtreme]

They used studs because you don't want to run bolts in and out of aluminum threads multiple times. Aluminum threads suck ass and cross thread/strip easily. All of the castings made at my work have heli coil inserts put in them. The threads would never last if they didn't.

I agree with Death on the heat idea. Another good idea is to soak the ******* in liquid wrench for a few days prior to working on them. It makes a huge difference.

My stud broke off too. I drilled it out and then used JB weld to repair the part of the casting that broke off too. Its held up for over a year now.

Good point.

Oh yeah, and JB Weld is the ****!