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!

[axiom-r]

You certainly did better than I did...  I tried to be careful and still broke a LH bit off in the hole. 

Nice work!  Lets see what it looked like!

T

[JohnnyTheCraneGuy]

Could've swore I had taken a pic of it broken in the head 

Either way here she is, my trophy!

I will say that I used the LT bit for all of the drilling. I'll be honest I took her slow the first 20 mins and then took a smoke break, said a few choice words and came back and just started sending it! I did go ahead and mark the depth on the drill bit with some tape about an 1/8 before it should've bottomed out. Full speed and literally 30 secs of drilling and the stud came up flush, grabbed that funky extractor and that's all she was really good for.

YMMV

[Waiex191]

grabbed that funky extractor and that's all she was really good for.

Truly a sign of end times and the coming armageddon!

Edit:

[JohnnyTheCraneGuy]

FUCK brother and you were so close  I still can't believe I was blessed by the piano gods and had good luck bestowed upon me

[fj1289]

That's exactly why I throw all the "extractors " out and only keep the drill bits.   

I've lost count how many broken studs and bolts I've removed with left twist drill bits.  I've only had one where I ruined the threaded hole - and that was a time I didn't center punch it well and the drill went way off center.  It seems the drill bit usually tears through and snags the thin edge of the bolt and backs it out just as it is about to start into the threads.