Snapped Header Bolt

[JohnnyTheCraneGuy]

Well as the title suggests I had this happen while out riding yesterday, on the top bolt for cylinder 3.

I might wait until I have everything for the front end swap or just pull the front end now to get the clearance I need to get in there. Or I was thinking I could swap the head from the 1100 case, but at that point which is more work right?

[JohnnyTheCraneGuy]

Oh and of course it's recessed into the head

[T Legg]

The torque setting for the exhaust flange nuts is only 11ft/lbs. When screwing the studs in they bottom out in the holes so I only go finger tight.
    Good luck removing it.

[fj1289]

Carefully center punch and VERY carefully left twist drill bits (available at harbor freight) with lots of PB Blaster.

NOTE! If you get or have a kit with the "easy outs" in it - throw the easy outs in the nearest garbage can - they are hard and brittle and will break off and you will be taking the head off for that repair!

[Waiex191]

NOTE! If you get or have a kit with the "easy outs" in it - throw the easy outs in the nearest garbage can - they are hard and brittle and will break off and you will be taking the head off for that repair!

From experience, that makes the job a lot easier.  You take the head off, throw it in the garbage or give it to a grownup, and put the head from your parts bike on.  This is what I did for my GN400.

[JohnnyTheCraneGuy]

Yeah thankfully there is a back to where those bolts thread into and I can just remove another bolt, measure the depth and tape the bit so I won't go to far. Fairly confident in getting it done but still 

[JohnnyTheCraneGuy]

Well I did it again boys!

Will post pics soon but left twist bits ftw!!

[fj1289]

Excellent!     

[FJ1200W]

Ah, nothing like the challenge of a snapped stud to start the day.....
Heat it up with a butane/propane torch, just hot, touch a crayon to it, then try to reverse it out with a pick.
A hammer and a pick, gently, if needed. Tap it in the direction of removal.
It will spin right out, simple.
If the star, moon and planets are all in alignment and you held your mouth just right.

[JohnnyTheCraneGuy]

butane and kroil for me was what worked for me, I've heard many great things about using a crayon too but I haven't tried it yet. Next time I'll have to give it shot!