exhaust flange bolts

[KillahTillah]

look what i did...i sheered off the lower bolt on the exhaust flange...wtf... what can i do now....don't have enought clearance to remove rear exhaust so is my only option to remove the other exhaust system? anyone have problems with the flange bolts on the head on the front of the engine???...please help and thank you....it's 2002 suzuki TL1000R...

[Rambunctous]

Post a pic of the other side of the bolt..

[keeena]

I have sheared a bolt head on the front cyl exhaust flange on the TLR; don't go at it ham-fisted. Hit it with some heat, PB, alternate CW/CCW & impact to help free the bolt.

[JohnnyV]

If I remember correctly Degsy has tackled this issue before.... common on TL's

EDIT: Nevermind, thought you meant you sheared off the stud at the cylinder

[Tricky Mike]

Is that a nut on the other side? Can it just get PB blasted and then punched out toward the nut side or is there not enough room?

[KillahTillah]

will try to post a pic for all on the other side of flange is a welded nut

[Tricky Mike]

Ah, it's welded.... If you have enough room for a center punch and a drill it looks like you've got a nice flat surface to start drilling on that bolt (I use left handed drill bits and heat on stuck bolts... Sometimes the bit grabs and turns the bolt out).

[KillahTillah]

yeah can't get a clear shot...i tried using a punch a realized i can do it with removing the left side exhaust....Might as well just do it right...just fear snapping the bolt on the front flange on the head....lol

[Tricky Mike]

Might want to get in there with some PB blaster and let it soak for an hour or two first.

[KillahTillah]

yeah gonnah have to work it.....and pray

[Tricky Mike]

Don't forget the anti-sieze when you put it back together.

[KillahTillah]

before
after

had to take the dreaded exhaust header bolts...

[KillahTillah]

it's going to need to be tapped....anyone have the skillz.....i have never done it...

[nhbubba]

Tap a hole? Anyone can. (I can, so really anyone can. )
But really, don't you just want to chase it?

[KillahTillah]

Tap a hole? Anyone can. (I can, so really anyone can. )
But really, don't you just want to chase it?

whats that??...not familiar with this ...?

[nhbubba]

Buy one of these in correct size:



Lubricate, maybe with some of this:



Stick in hole.
Turn.
Repeat as necessary.

[G21forme]

Turn back out, turn back out, repeat as necessary if you have patience it works the balls. Saved my bacon once or twice.

[KillahTillah]

oh boy do I have patience I will get right on it...

[KillahTillah]

Buy one of these in correct size:



Lubricate, maybe with some of this:



Stick in hole.
Turn.
Repeat as necessary.

so i should try with my current size bolt and upsize if necessary?

[jbmass]

current bolt size, that steel is hard. Did you get the broken bolt out?

Just finished building a TL, and I still have another. I know these bike very well.

[jbmass]

And use cutting oil, so much better than WD. I have a tap set if you want to borrow it, I'll be in Hudson, Ma working in my garage this weekend. Or just bring the piece over.

[KillahTillah]

yeah here it is.....don't know how the fuck those threads got fucked up like that.....but you know then that it's just a nut welded to the flange that holds these bolts in....this is the flange that connects the left and right exhaust....

[jbmass]

Overtightening, no use of washers, no anti-sieze, electrolysis, and a combination of all of the above. replace those exhaust gaskets, they pop right out. I have 2 new ones if you need some.

[KillahTillah]

Overtightening, no use of washers, no anti-sieze, electrolysis, and a combination of all of the above. replace those exhaust gaskets, they pop right out. I have 2 new ones if you need some.

yeah i have that gasket Thanks ...and i was initially replacing the damn rear cylinder donut gasket it was half gone...so i counted on replacing the flange gasket ....but i had to take the whole left side off to get this right side out to free the frozen bolt.....it sucked...so all new gaskets and bolts have been ordered...lol

[KillahTillah]

Damn i never finished this thread......got all caught up when i had to re-thread the damn oil drain plug....Thanks for all your help JBmass i can't thank you enough bud.....one day i will come back to yah....Thanks